High strength polymer of hydroquinone poly(iso-terephthalate) containing residues of p-hydroxybenzoic acid

ABSTRACT

This invention pertains to novel copolyesters consisting essentially of units (I), (II), (III), and (IV). ##STR1## and blends of these polymers and articles made from both. Units (I), (II), (III), and (IV) are present in specified proportions as defined in the &#34;Description of the Invention&#34;. 
     The instant copolyesters display orientation in the molten state, good fiber ratings and high strength. Advantageously, the polymers of the present invention display a significant improvement in viscosity and moldability of the neat polymer. The polymers have excellent mechanical and surface properties including blister resistance, strength, toughness, and ability to vapor phase solder, and form strong fibers while still maintaining a high heat distortion temperature. They have melting points in the range of from about 250° to about 360° C. and are melt-processible. Advantageously, these compositions filled with about 30 weight percent of glass fibers display heat distortion temperatures of up to 240° C., when measured under a load of 264 psi. The polymers may be blended to tailor properties. These polymers and blends may be used advantageously in producing fibers and in electrical equipment, electronic components and other end uses requiring moderately high temperatures.

This is a continuation-in-part of U.S. Ser. No. 255,670, filed Oct. 11,1988, and a continuation-in-part of U.S. Ser. No. 255,632, filed Oct.11, 1988.

FIELD OF THE INVENTION

This invention pertains to novel copolyesters consisting essentially ofunits (I), (II), (III), and (IV). ##STR2## and blends of these polymersand articles made from both. Units (I), (II), (III), and (IV) arepresent in specified proportions as defined in the "Description of theInvention."

The instant copolyesters display orientation in the molten state, goodfiber ratings and high strength. Advantageously, the polymers of thepresent invention display a significant improvement in viscosity andmoldability of the neat polymer. The polymers have excellent mechanicaland surface properties including blister resistance, strength,toughness, and ability to vapor phase solder, and form strong fiberswhile still maintaining a high heat distortion temperature. They havemelting points in the range of from about 250° to about 360° C. and aremelt-processible. Advantageously, these compositions filled with about30 weight percent of glass fibers display heat distortion temperaturesof up to 240° C., when measured under a load of 264 psi. The polymersmay be blended to tailor properties. These polymers and blends may beused advantageously in producing fibers and in electrical equipment,electronic components and other end uses requiring moderately hightemperatures.

BACKGROUND OF THE INVENTION

Wholly aromatic polyester resins have long been known. For instance,4-hydroxybenzoic acid homopolymer and copolymers have been described inthe past and are commercially available. Such polymers commonly arecrystalline in nature and, when molten, frequently exhibit orientationin the melt; however, they have relatively high melting points orpossess a decomposition temperature which is below the melting point,which leads to great difficulty in processing.

The homopolymer of p-hydroxybenzoic acid is a very high melting,insoluble material and, hence, very difficult to fabricate. Meltingpoints as high as 610° C. were quoted--see W. J. Jackson, The BritishPolymer Journal, December 1980, p. 155. In order to depress the highmelting point of the homopolymer so as to make it melt fabricable, avariety of materials incorporating different types of comonomers wereprepared over the years.

One such material is, for example, the resin made from p-hydroxybenzoicacid, isophthalic and/or terephthalic acids and 4,4'-biphenol asdescribed in Cottis et al., U.S. Pat. Nos. 3,637,595 and 3,975,487. Thepolymer has outstanding high temperature properties and can be molded togive articles of high modulus and strength. It is offered commerciallyby Amoco Performance Products, Inc. under the trademark of Xydar®.

The main drawback of the prior art p-hydroxybenzoic acid copolymers isthe relatively high cost associated with the use of an expensivecomonomer, such as 4,4'-biphenol, substituted hydroquinones (e.g.,phenylhydroquinone), naphthalene diols, naphthalene dicarboxylic acids,and hydroxy-naphthoic acids. Efforts to replace these expensive monomerswith the significantly less expensive hydroquinone, which is disclosedas an equivalent of biphenol in the aforementioned U.S. Pat. Nos.3,637,595 and 3,975,487, were made by several research groups; however,none of these investigations were successful.

Study of the prior art shows that replacement of 4,4'-biphenol withhydroquinone leads to materials with inferior properties. The problemcreated by the introduction of hydroquinone is basically the following:at high terephthalate contents, high melting generally intractablepolymers are obtained; tractability may be achieved at higherisophthalate levels, but the polyesters are relatively low melting andoften display low second order glass transition temperatures which leadto low moduli and low heat distortion temperatures. For example,polyesters from p-hydroxybenzoic acid (PHBA) isophthalic acid (IA) andhydroquinone (HQ) were prepared by Deex, U.S. Pat. No. 4,377,681. Atmole ratios PHBA/IA/HQ of 33.3/33.3/33.3 the material had a glasstransition temperature of 110° C.; when the above coreactants were usedat ratios of 50/25/25, a Tg of 115° C. was obtained.

The high melting points of a series of p-hydroxybenzoicacid/terephthalate acid/hydroquinone copolymers are graphicallyillustrated in FIG. 2 of the paper by G. W. Calundann, IndustrialDevelopment of Thermotropic Polyesters in High Performance Polymers:Their Origin and Development 235-249 (R. B. Seymour and G. S.Kirshenbaum, editors 1986). The publication shows clearly (in FIG. 2)that hydroquinone polymers melt at considerably higher temperatures thantheir 4,4'-biphenol counterparts. The T_(m) of the lowest meltingcomposition shown is about 420° C. FIG. 4 of the same publication (p.243) indicates how one research group was able to depress the meltingpoints of the subject polymers by incorporating naphthalene diols,naphthalene dicarboxylic acids, and hydroxy naphthoic acids into them.From a purely technical point of view, the latter approach was asuccess; however, the modified polymers were still expensive due to thehigh cost of the naphthalene-based monomers.

The intractability of the hydroquinone-derived materials is discussed inJackson et al., U.S. Pat. No. 4,242,496. Column 2, lines 18-26, states:

"U.S. Pat. No. 3,637,595 discloses that aromatic liquid crystalpolyesters prepared from terephthalic acid, hydroquinone and varyingamounts of p-hydroxybenzoic acid melt in the general range of 800° to900° F. Obviously, the melting point of these polymers is far too highand the thermal stability is insufficient to permit these polymers to beused in conventional melt-processing equipment."

It is further stated (column 2, lines 33-40) that a solution to theabove problem

"was to incorporate a substituent on some of the aromatic rings of thepolyester, preferably on the diol ring. For example, it is well knownthat use of chloro, methyl or ethyl hydroquinone lowers the meltingpoint of the polyester. Although this approach can be used to lower themelting point, typically the mechanical properties are alsosubstantially reduced."

The patent goes on to propose the use of phenyl hydroquinone (anexpensive comonomer) as the best way whereby the melting point can bereduced to obtain tractable resins, without adversely affecting themechanical properties.

As indicated earlier, polyesters forming oriented melts were made from avariety of substituted hydroquinones. See, for example, Lee et al., U.S.Pat. No. 4,600,765; Hutchings et al., U.S. Pat. Nos. 4,614,790 and4,614,791; and Funakoshi et al., U.S. Pat. No. 4,447,593. Readilyprocessible polyesters made from p-hydroxybenzoic acid, isophthalic andoptionally terephthalic acid, hydroquinone and 3,4'- and/or4,4'-biphenol, 3,4'-and/or 4,4'-dihydroxydiphenyl ether, 3,4'-and/or4,4'-dihydroxydiphenyl sulfide are the subject of Dicke et al., U.S.Pat. No. 4,603,190. It should be recognized that once again an expensivemonomer is necessary to obtain tractable melts. Similar situations areencountered in a host of other U.S. and foreign patents. See, forexample: Portugall et al., European Patent Appln. No. EP-257,558; Hisgenet al., European Patent Appln. No. EP-257,598; Hisgen et al., GermanPatent Appln. No. DE-3,629,208; Hisgen et al., German Patent Appln. No.DE-3,629,210; and Okamoto et al., World Patent Application No.WO-88/00,955.

As pointed out above, tractable materials result at high isophthalicacid levels but the products typically display undesirably low glasstransition temperatures. Deex, U.S. Pat. No. 4,377,681 states (column 1,lines 31-38):

"For example, liquid crystal copolyesters have been prepared from thefollowing fairly rigid molecular species: p-hydroxybenzoic acid,hydroquinone and isophthalic acid. However, when ratios of the monomersare selected to provide tractable polymers, the glass transitiontemperature is generally low and the high temperature mechanicalproperties are reduced."

Attempts to increase the Tg of these products have been made. Thus,Deex, U.S. Pat. No. 4,377,681, claims copolyesters prepared fromp-hydroxybenzoic acid, isophthalic acid, hydroquinone and2,2-bis(4-hydroxyphenyl)propane. The preferred compositions contain fromabout 20 to about 35 mole percent of p-hydroxybenzoic acid units, andfrom about 5 to about 12 mole percent of 2,2-bis(4-hydroxyphenyl)propane (bisphenol-A) based on the total diphenol components.Glass transition temperatures of about 175° to about 190° C. wereobserved in these polymers. These values represent an improvement whencompared to the Tg's of the polyesters mentioned supra. However, theymust be considered low as they lead to heat distortion temperatures(HDT's) which are, at best, of the order of about 120° to 140° C.;moreover, the introduction of bisphenol-A lowers the degree ofcrystallinity and the rate of crystallization which we believe, as willbe discussed infra, leads to lower HDT's. In addition, mold shrinkage ofthese copolymers is unsatisfactorily high.

Park U.S. Pat. No. 4,816,552 is directed to polymers prepared by heatinga mixture of a 4-acetoxybenzoic acid derivative, a hydroquinonediacetate derivative, a dicarboxylic acid, and a4-acetoxy-(4-acetoxyphenyl) benzoate derivative in two steps to removegenerated acetic acid and form the polymer.

This patent is directed specifically to block copolymers with a specificsequence of recurring units. It reportedly has improved spinningprocessability. Our present invention is produced in a manner well knownin the art to produce a random copolymer. As shall be shown infra, ourinvention is produced by the acidolysis method as disclosed in U.S. Pat.No. 3,637,595 which Park acknowledges produces a "partial block," i.e.,a random copolymer (U.S. Pat. No. 4,816,552 col. 2, 1. 24). Park furtherstates that polymers made by that method have no practical use due tohigh melting point, high viscosity, and inferior processability (U.S.Pat. No. 4,816,552 col. 2, 1. 15-32).

The dilemma facing those who have attempted the development oftractable, high HDT, hydroquinone/benzene dicarboxylicacid/p-hydroxybenzoic acid copolyesters is perhaps best illustrated byExample 1 of Cottis et al., U.S. Pat. No. 3,975,487. A polyester havingexcellent properties, based upon a 1:3 molar ratio ofisophthalic:terephthalic acids, p-hydroxybenzoic acid, and 4,4'-biphenolwas prepared. When this example was repeated using hydroquinone in placeof biphenol and all isophthalic acid as the dicarboxylic acid, a polymerhaving poorer properties (i.e., a lower flexural strength and a lowermodulus) was obtained (column 10, lines 60-63).

Copolyesters based on p-hydroxybenzoic acid (PHBA), hydroquinone (HQ),isophthalic (IA) and terephthalic (TA) acids are disclosed in Cottis etal., U.S. Pat. No. 3,637,595. Cottis shows one example in which a resinincorporating all of the four monomers is described (Example 10). Thepolymer was formed from 1.0 mole of PHBA, 0.5 moles of IA, 0.5 moles ofTA, and 1.0 moles of HQ. It was poorly characterized; weight loss inair, at 752° F. was apparently high, indicating thermal stabilityproblems. Our own characterization of the resin produced by thepreferred process utilized in this invention (see Experimental,Comparative Example 2 also designated as "X" produced a low HDT (214°C.)).

Thus, the elusive goal of developing low cost hydroquinone-basedcrystalline polymers which (1) display a significant improvement inviscosity and moldability of the neat polymer and (2) have excellentmechanical and surface properties including blister resistance,strength, toughness, and (3) ability to vapor phase solder, and formstrong fibers while still maintaining a high heat distortion temperaturehas not been achieved in the prior art. These polymers, when filled with30 percent by weight of glass fibers, maintain (1) an HDT of 240° C.,(2) melt-processability below the decomposition temperature of about415° C., (3) a melting point in the range of 250° to 360° C. Based onthe prior art, it appeared unlikely that polymers having theseproperties could be produced, particularly polymers consistingessentially of units (I), (II), (III), and (IV). Furthermore, eventhough the overall combination of properties of the neat unblendedpolymers is outstanding, they may be tailored for different end useapplications by blending.

It has now also been discovered that the addition of the 1 to 19 partsby weight of a first polyester polymer (a) comprising recurring moietiesof dihydroxyarylene comprising hydroquinone; a nonvicinal benzenedicarboxylate (preferably terephthalic acid and mixtures of terephthalicacid and isophthalic acid) and p-oxybenzoate to a one part by weight ofa second polyester polymer (b) comprising recurring moieties ofnaphthalene based monomers and/or diphenol; nonvicinal benzenedicarboxylate and p-oxybenzoate, wherein said units are present inspecified proportions, yields alloys in which the tendency to blister issubstantially reduced or eliminated and also having increased strength,higher HDT's, and excellent fabricability.

The preferred mole ratios of monomers of the base polyester polymer (a)are depicted in the triangular diagrams and are described infra. Thepolymers melt in the range of from about 250° to about 360° C. Ofparticular interest are the polyesters falling into area C of FIGS. 1and 2.

With some known exceptions, mixtures of polymeric materials aregenerally immiscible. That is, they consist of domains of chemicallydistinct phases. Usually, one component forms a continuous phase, whilethe other component forms roughly spherical domains as inclusions. Undersome circumstances, bi-continuous structures are also obtainable. Mixingtwo arbitrarily chosen polymers usually results in inferior materialshaving no utility, since in the absence of adhesion between phases, thedispersed phase merely weakens the continuous phase. Some polymericproducts, such as the wholly aromatic polyesters, exhibit an orderedstructure in at least some regions of the polymer. This order can existin one, two or three dimensions. The incorporation into blends ofpolymers exhibiting an ordered structure leads to an increased tendencyof the blends to separate into phases. This is believed to be due to thefact that the order found in certain regions of the resin causes afairly sharp boundary between the domains of the molecules of thecomponent polymers. Hence, blends including such polymers would beexpected to exhibit a significant reduction in properties.

It should be noted, however, that many useful blends whose morphologyand phase interaction are favorable, are known.

Cottis, U.S. Pat. No. 4,563,508, is directed to the improvement ofmolding compounds based on wholly aromatic polyesters by the addition ofa minor amount of a flow modifier. The flow modifier crystallizes poorlyand improves the flow of the highly crystallized base polymer it isadded to. The flow modifier does not enhance the end properties of theblend composition. It is to be noted that the addition of the flowmodifier decreases the HDT of the composition and does not increase thestrength.

Takayanagi et al., U.S. Pat. No. 4,228,218, discloses a polymercomposition comprising 20 percent or less, based upon the total weightof polymeric material, of a first rigid polymer with the balance being asecond polymer composed substantially of flexible molecular chains. Thefirst polymeric material is dispersed in the second polymeric materialin a microscopic region of 1 μm or less. It is believed that whollyaromatic polyesters would be characterized by those skilled in the artas rigid molecules within the context of the above cited patent. Thepatent does not disclose blends of two or more polymers having rigidchains with improved blister resistance as does the present invention.

Blends of polymers exhibiting orientation in the melt with otherpolymers were investigated. Mixtures of liquid crystalline polyesterswith poly(alkylene terephthalates), polycarbonates and polyarylates weredescribed in Cincotta et al., U.S. Pat. Nos. 4,408,022 and 4,451,611;Froix, U.S. Pat. Nos. 4,489,190 and 4,460,735; and in Kiss, EuropeanPatent Application No. 169,947. Improved mechanical properties werefound with these materials. The addition of a particular liquid crystalpolymer to poly(butylene terephthalate) or other thermoplastic polymerswas described as a method to obtain compositions with enhancedresistance to melt dripping during burning (see Kim et al., U.S. Pat.No. 4,439,578). In several instances, e.g., in alloys of liquidcrystalline polyesters with an aromatic sulfone polymer (Froix et al.,U.S. Pat. No. 4,460,736) with an aromatic poly(ester amide) (Kiss, U.S.Pat. No. 4,567,227), and with poly(arylene sulfides) (Froix, U.S. Pat.No. 4,276,397) improved mechanical characteristics and improvedprocessability (lower viscosity) of the non-anisotropic resin werenoted. Better properties were also obtained by blending two particularliquid crystalline polyesters (see, for example, Froix, U.S. Pat. No.4,267,289).

Liquid crystalline materials, including polyesters, were used todecrease the viscosity and improve the processability of a number ofother resins, including fluorinated polyolefins (see Bailey et al., U.S.Pat. No. 4,417,020; Cogswell et al., U.S. Pat. Nos. 4,429,078 and4,438,236; and George et al., U.S. Pat. No. 4,650,836).

In one instance (Bailey et al., U.S. Pat. No. 4,508,891), it was claimedthat the addition of an isotropic resin to an anisotropic resin leads toa decrease of anisotropy in the corresponding molded articles.

The fracture-surface morphology of thermotropic 6-hydroxy-2-naphthoicacid-p-hydroxybenzoic acid copolymer blends with nylon 6, poly(butyleneterephthalate), and polycarbonate prepared by screw injection molding,was studied by Beery et al. J. Mater. Sci. Lett. 1988, 7(10), pp.1071-3. The morphology was found to be strongly dependent on the flowhistory and on the composition of the subject mixtures.

A commonly assigned patent application entitled "Extrusion-GradeCompositions Comprising Mixtures of Wholly Aromatic Polyesters," Ser.No. 060,038, filed on Jun. 9, 1987, in the names of Field et al., nowU.S. Pat. No. 4,851,480, hereby incorporated by reference, describesalloys of a first polyester comprising recurring moieties of4,4'-biphenol, terephthalate, and p-oxybenzoate; with a second polyestercomprising the same recurring moieties, but wherein the proportion ofthe p-oxybenzoate units is higher than in the first polyester. Theapplication discloses that while each individual polyester is difficultto extrude into acceptable products, their alloys provide good extrusiongrade compositions. Molding compositions comprised of the above firstand second polyester, filler, and optionally a polymeric flow modifierare claimed in commonly assigned U.S. patent application entitled"Molding Compositions Comprising Mixtures of Wholly Aromatic Polyestersand Fillers," Ser. No. 060,114 filed on Jun. 9, 1987 in the name of J.J. Duska, hereby incorporated by reference.

Thus, it is known from the prior art that it is possible to alloy twopolyesters, wherein said polyesters are based on identical monomers butdiffer in the relative proportion of the monomers, wherein each of saidpolyesters has unsatisfactory molding and extrusion characteristics andobtain good molding and extrusion grade compositions.

No reference is known which is directed to the improvement of surfaceand thermal properties (i.e., blistering, strength, and HDT) by blendingtwo polymers having orientation in the melt. A feature of the instantinvention that is totally unexpected and highly remarkable is the factthat compatible blends showing good mechanical and surface propertiesare achieved by alloying two crystalline wholly aromatic copolyestersprepared from monomers having totally different structures, e.g.,phenylene versus naphthalene or biphenylene. The enhanced blisterresistance is particularly astonishing. Indeed, while the blisterphenomenon is not fully understood, it has been attributed tonon-homogeneity in random copolymers. In any event, as indicatedearlier, alloys of materials having ordered structures would be expectedto have reduced properties. Hence, the instant discovery was highlysurprising and totally unexpected.

It is the general object of the present invention to provide novel,inexpensive, highly melt-processible hydroquinonepoly(iso-terephthalates) containing residues of p-hydroxybenzoic acidpolymers which form a highly tractable oriented melt phase, and whichare capable of melt extrusion to form quality, high performance fibers,films, three-dimensional molded articles, etc. The polymers display highHDT's which are essential in certain high heat applications. They haveexcellent flexural and tensile strength, they have the ability to vaporphase solder, and produce good fibers. When blended with other polymersthey produce inexpensive high heat polymers capable of high HDT's andstill produce an attractive tough blister-resistant surface.

It is a further object of the present invention to provide novel,melt-processible hydroquinone poly(iso-terephthalates) containingresidues of p-hydroxybenzoic acid, polymers which form a melt phasebelow 400° C. in the substantial absence of polymer degradation, unlikemany other polymers which include relatively high concentrations of the4-oxybenzoyl moiety.

These and other objects, as well as the scope, nature and utilization ofthe invention will be apparent to those skilled in the art from thefollowing detailed description.

THE INVENTION

It was unexpectedly discovered that copolyesters, consisting essentiallyof units (I), (II), (III), and (IV) ##STR3## where p is approximatelyequal to q+r; the values of p, q, r and s are as hereinbelow defined;and having molecular weights in the range of from about 2,000 to about200,000, display an outstanding combination of properties. The subjectpolymers form a stable oriented melt phase at 250° to 360° C., the meltphase is tractable, and the polymers display a significant improvementin moldability and can be melt-extruded below its decompositiontemperature to form quality, high performance fibers, films, moldedarticles, and the like. Fabricated products show good surfaceproperties, high strength, and good retention of properties at hightemperatures. Advantageously, materials filled with 30 percent by weightof glass have heat distortion temperatures of over 200° to about 240° C.and higher, under a load of 264 psi. It is believed that the higher theamount of crystallinity of the polymer the higher the heat distortiontemperature (HDT) will be, also the higher the melting point.Unfortunately, high melting point polymers necessitate high molding orstock barrel temperatures for compounding. Due to the properties of thepresent invention including lower melting point and rheology, we areable to process at a lower temperature and still achieve high HDTpolymers.

Some of the preferred novel copolymer compositions which combine theabove-mentioned outstanding properties are plotted in the triangularphase diagram FIG. I. The diagram shows the compositional area ofinterest, area C. The coordinates for each point of this area define acopolyester in terms of percentages of p-oxybenzoyl, hydroquinoneterephthaloyl and hydroquinone isophthaloyl units. Percentages for graphpurposes of p, q, r and s can be calculated from the molar compositionsby assuming p is constant at 1.0 mole and by adding the total moles ofq/r/s as the denominator and dividing that into the moles of eachmonomer, thereby calculating the percentage of each constituent. Forexample, if the molar concentration of q/r/s/p, respectively, are:0.5/0.5/0.25/1.0, the percentages are ##EQU1##

As indicated above, the properties of the polymer are somewhat dependenton the method of synthesis. It should be noted that the criterion forborderline compositions on the phase diagram is that the HDT as measuredon 30 percent glass-filled products under a load of 264 psi is about200° to about 240° C. and a fiber pull rating of 2 to 3 is achieved.Accordingly, those polymers are considered as falling within the scopeof the instant invention.

It is important to point out that melting points, HDT's, crystallizationtemperatures and crystallization rates are basic property parametersthat determine polymer performance. Thus, a very high melting pointabove 400° C. results in materials that are either difficult tomelt-fabricate or plain intractable (vide supra). Lower melting pointslead to resins having lower HDT's. High heat distortion temperatures arevery important in certain applications since they indicate the uppertemperature at which the particular polymer is useful, especially instructural applications.

As indicated earlier, two additional useful characteristics of theinstant copolyesters are their crystallization temperature andcrystallization rate. By crystallization temperature is meant thetemperature at which onset of crystallization takes place; it isgenerally in the range of from 240° to 315° C. The crystallization rateis expressed as an increase in counts per minute as measured by X-raytechniques (see below); this increase is of the order of less than 1,000counts per minute. Crystallization temperatures and rates ofcrystallization are related to the degree of crystallinity of thematerial. If these two parameters are low, the high temperaturecharacteristics of the polyester may develop slowly. On the other hand,if the above two parameters are too high, standard molding of thepolymer becomes difficult and more severe fabrication conditions (e.g.,higher temperatures), or techniques such as compression molding, impactmolding or plasma spraying have to be utilized.

Melting points, crystallization temperatures and rates ofcrystallization were determined using X-ray techniques. A briefdescription of these techniques follows.

The crystalline melting point is measured by following the intensity ofthe X-ray diffraction of the most intensive peak as a function oftemperature. The most intensive diffraction peak is located at a spacingof about 4.5 Å. Based on literature data [J. Polymer Sci., Polym. Chem.Ed., 14, 2207 (1976); J. Polymer Sci., Polym. Chem. Ed., 21, 2249(1983)], the subject peak has been tentatively assigned to the distancebetween the polymer chains. The point at which the intensity reaches aminimum is considered for the polymer melt temperature. The rate oftemperature change is 100° C. per minute.

The onset of crystallization is taken as the temperature at which thereis a sharp increase in the intensity of the X-ray peak referred toabove. Again, the rate of cooling is 100° C. per minute.

Crystallization rate is defined as the difference between theintensities of the above X-ray peak at the crystallization temperatureand at 40° C. below that temperature, the rate of cooling being 100° C.per minute.

A detailed description of the three methods is given in theExperimental. Note that throughout this patent, all melting andcrystallization data refer to the second heating/cooling cycle of thesample (see Experimental).

It is important to note that the instant invention does not reside inthe use of novel monomers; the critical factor of the present inventionis the discovery that polymers having the particular combination ofphysical properties can be obtained when the four monomers, i.e.,p-hydroxybenzoic acid (PHBA), hydroquinone (HQ), isophthalic acid (IA)and terephthalic acid (TA), are used in certain amounts and are producedby the preferred method.

The metes and bounds of the present invention have been defined by thecircumscribed area of C in FIG. 2 in conjunction with the aforementionedphysical properties.

While it is difficult to calculate a numerical range of monomer units,for convenience, the following ratios are given: The most preferred typeof polymers are depicted in area C and have the following approximatemonomer ranges based on moles: s≈0.075 to 1.5; q≈0.58 to 0.050; andr≈0.42 to 0.95. Particularly, area C is bound by the following:

when

s≈1.5

q≈0.3 to 0.050

r≈0.7 to 0.95

when

s≈0.075

q≈0.58 to 0.33

r≈0.42 to 0.67

It is to be noted that there may be polymers that fall within area C andin the above ranges that would be outside of the scope of the presentinvention as defined by the physical properties required. As indicatedearlier, the compositional areas which cover the materials of thisinvention are depicted on the attached triangular phase diagram FIG. 2.Clearly, their existence was neither anticipated nor predicted by theexisting prior art.

The synthesis of the polyesters of the instant invention is describedgenerally in Cottis et al., U.S. Pat. No. 3,637,595 entitled"P-Oxybenzoyl Copolyesters," and in Finestone, U.S. Pat. No. 4,742,149entitled "Production of Melt Consistent Aromatic Polyesters"; thedisclosure of the aforementioned two patents is incorporated herein byreference.

The bulk condensation of aromatic polyesters is described in the patentliterature and broadly considered involves an alkanoylation step inwhich a suitable dicarboxylic acid, hydroxybenzoic acid and diol arereacted with an acid anhydride; a prepolymerization step in which thereaction product of the first step is polycondensed to prepare aprepolymer; and the prepolymer is thereafter heated in a third step toproduce a polycondensate of the desired degree of polymerization.

Thus, in somewhat greater detail, the instant copolyesters are preparedby charging into the reactor the required amounts of isophthalic andterephthalic acids, p-hydroxybenzoic acid and hydroquinone. An anhydrideof a lower monocarboxylic acid, preferably an anhydride of a C₂ to C₄monocarboxylic acid, is added in at least stoichiometric amounts. It ismost preferred to use acetic anhydride; its amount is preferably fromabout 5 to about 20 mole percent over that required for the acetylationof all of the hydroxyl groups. The acetylation reaction takes place atabout 140° C. for a period of time of from about 2 to about 6 hours. Thereaction mixture is then heated to about 240° to 320° C. at a rate ofabout 10° to 40° C. per hour, and is kept at about 240° to 320° C. forapproximately a few minutes to about 4 additional hours. The lowmolecular weight polymer obtained is then solid state advanced to therequired high molecular weight by heating to a temperature of from about265° to about 340° C., for a period of time of from about one to about24 hours.

A preferred variant as described in Finestone, U.S. Pat. No. 4,742,149,comprises adding a salt, particularly an alkaline earth metal salt or analkali metal salt, preferably potassium sulfate, during the preparationof the resin and particularly to the prepolymer melt prior toadvancement of the final product to the desired degree ofpolymerization. The incorporation of stabilizing amounts of phosphites,as described in Cottis, U.S. Pat. No. 4,639,504 is also advantageous.

The polyesters of the present invention commonly exhibit ##STR4## endgroups depending upon the synthesis route selected. As will be apparentto those skilled in the art, the end groups optionally may be capped,e.g., acidic end groups may be capped with a variety of alcohols, andhydroxyl end groups may be capped with a variety of organic acids. Forinstance, end capping units such as phenyl ester ##STR5## optionally canbe included at the end of the polymer chains.

The polymers can be annealed below their melting points for a period oftime or the polymers may be oxidatively crosslinked to at least somedegree, if desired, by heating in an oxygen-containing atmosphere (e.g.,in air) while in bulk form or as a previously shaped article at atemperature below their melting points for a limited period of time(e.g., for a few minutes).

The polyesters of the present invention tend to be substantiallyinsoluble in all common polyester solvents such as hexafluoroisopropanoland o-chlorophenol, and accordingly are not susceptible to solutionprocessing. They can surprisingly be readily processed by known meltprocessing techniques as discussed hereafter.

The polyesters of the present invention commonly exhibit weight averagemolecular weights of about 2,000 to about 200,000.

The instant polyesters can be melt processed in the substantial absenceof polymer degradation to form a variety of relatively stiff shapedarticles, e.g., molded three-dimensional articles, fibers, films, tapes,etc. The polyesters are suitable for molding applications and may bemolded via standard injection molding techniques commonly utilized whenforming molded articles. It is particularly important to note thatunlike the polyesters commonly encountered in the prior art, it is notessential that more severe injection molding conditions (e.g., highertemperatures), compression molding, impact molding, or plasma sprayingtechniques be utilized. Fibers or films may be melt extruded. Fibercapabilities are especially good in this composition. Of course, in someinstances, as described in Cottis et al., U.S. Pat. No. 4,563,508, meltfabrication may be facilitated by adding flow aids.

The polymers of this invention may contain up to 10 mole percent (basedon total reactants) of carbonate linkages and/or aromatic comonomersother than (I)-(IV), such as biphenol, provided that the use of saidcarbonate linkages and/or comonomers does not unfavorably affect thevery attractive properties of the instant copolyesters.

As stated supra, the present invention provides also an improved blendof two wholly aromatic polyester polymers. As used herein, the term"blend" includes any physical blend, mixture, or alloy of the polymericcomponents. The aromatic polyesters are considered to be "wholly"aromatic in the sense that each moiety present in the polyestercontributes at least one aromatic ring to the polymer backbone.

Blends comprising about 1 to about 19, preferably about 1.5 to about 9,parts by weight of a first polyester (a) comprising units (I), (II),(III) and (IV): ##STR6## where p is approximately equal to q+r; q is inthe range of from about 0.05 to about 0.76; r is in the range of fromabout 0.95 to about 0.24; s is in the range of from about 0.10 to about9.0 moles per each mole of unit (I), and where said first polyester hasa melting point of from about 250° to about 360° C.; and (b) one part byweight of a second polyester comprising units (IX), (X) and (XI):##STR7## wherein e is approximately equal to f; e is one; and g is inthe range of from about 1.5 to about 5, preferably in the range of fromabout 2 to about 4 moles, per each mole of monomer corresponding to unit(IX); where the molecular weight of said polyesters (a) and (b) are inthe range of from about 2,00 to about 200,000; are easy to meltfabricate, display vastly improved moldability, yield parts pleasing tothe eye; and, surprisingly, show a reduced tendency to blister onmolding. A totally unexpected and surprising feature of the instantblends is that both their moldability and the surface characteristics ofthe molded objects obtained from them, are generally better than thecorresponding properties of the individual polyesters. In addition, thematerials display improved mechanical properties over those of theconstituent polymers. Heat distortion temperatures, both on neat or on30 percent by weight glass fiber filled compositions, are at least 200°C. and may be as high as 350° C. and higher under a load of 264 psi.

The novel copolyesters of the present invention yield particularlyinteresting blends comprising a first polyester comprising units derivedfrom a dihydroxyarylene consisting essentially of dihydroxybenzene anddihydroxybiphenyl; nonvicinal benzene dicarboxylic acids andp-hydroxybenzoic acid; and a second polyester comprising units derivedfrom at least one of a naphthalene-based monomer and units derived froma diphenol, a nonvicinal benzene dicarboxylic acid and p-hydroxybenzoicacid.

More particularly, it was discovered that blends comprising about 1 toabout 19, preferably about 1.5 to about 9, parts by weight of a firstpolyester (a) to about 1 part by weight of a second polyester (b), andwherein (a) comprising units (I), (II), (III) and (IV): ##STR8## where pis approximately equal to q+r; q is in the range of from about 0.05 toabout 0.76; r is in the range of from about 0.95 to about 0.24; s is inthe range of from about 0.10 to about 9.0 moles per each mole of monomercorresponding to unit (I); and where said first polyester has a meltingpoint of from about 250° to about 360° C.; (b) comprising units (V),(VI), (VII) and (VIII): ##STR9## where a is approximately equal to b+c;b is in the range of from about 0.5 to about 0.8; c is in the range offrom about 0.5 to about 0.2; and d is in the range of from about 1 toabout 7, preferably from about 2 to about 4 moles per each mole of unit(V) where said polyesters (a) and (b) have molecular weights in therange of from about 2,000 to about 200,000, are easy to melt fabricateand yield injection molded parts that surprisingly show a significantlydecreased tendency to blister. In addition, the materials generallydisplay improved mechanical properties over those of the constituentpolymers, as well as improved processibility, composites containingabout 30 weight percent of glass fibers, have heat distortiontemperatures (HDT's) of at least 240° C., when measured under a load of264 psi.

Some of the compositions corresponding to the wholly aromatic polyestersof the first polyester (a) are plotted on the triangular diagram FIG. 1as discussed supra. The coordinates for each point of this area definesa copolyester in terms of molar percentages of monomer units. Thepolymers of area C (FIG. 2) are characterized in that they display asignificant improvement in viscosity and moldability of the neatpolymer. The polymers have excellent mechanical and surface propertiesincluding blister resistance, strength, toughness, and ability to vaporphase solder, and form strong fibers while still maintaining a high heatdistortion temperature. The polymers are melt processible below theirdecomposition temperatures, and their melting points are in the range of250° to 360° C.

Also, the instant invention comprises blends of from about 1 to about 19to about 5 to about 95 parts by weight of a first polyester polymer (a)comprising units (IX), (X), (XI) and (XII): ##STR10## where n is 1 or 1and 2; the number of moles of unit (IX) is approximately equal to thenumber of moles of units (X) and (XI); or a first polyester comprisingunits (IXb), (IXc), (XIa), (XIIa): ##STR11## wherein e'+e" isapproximately equal to f+g; the ratio of e' to e" is from about 3:1 toabout 99:1; the ratio of f to g is from about 0.42:1 to about 10:1; andthe ratio of h to f+g is from about 0.15:1 to about 8.0:1 moles per onemole of monomers corresponding to the sum of units (IXb)+(IXc); per onepart by weight of a second polyester polymer (b) comprising at least 1unit: ##STR12## wherein Ar comprises at least one member selected fromthe group consisting of: ##STR13## X₁ and X₂ are independently selectedfrom the group consisting of oxy and carbonyl; optionally in conjunctionwith at least one unit comprising monomer (XVIII): ##STR14## wherein X₁and X₂ are as previously defined, and the Ar group of the secondpolyester may also comprise a divalent aromatic radical comprising atleast one phenylene group such as phenylene, biphenylene andoxybiphenyl; both polyesters having molecular weights of from about2,000 to about 200,000.

The instant blends are generally easier to melt fabricate, displayimproved moldability and yield parts pleasing to the eye with goodsurface characteristics. Unexpectedly, the materials have improvedmechanical properties that are quite often superior to the properties ofthe two constituent polymers. Heat distortion temperatures, both on neatand on 30 percent by weight glass filled blend compositions, are atleast 175° C. and may be as high as 300° C. and even higher, whenmeasured under a load of 264 psi.

As indicated above, the first wholly aromatic polyester useful in thelast series of blends of the instant invention comprises units (IX),(X), (XI), (XII), (IXb), (IXc), (Xa), (XIa) and (XIIa). A vast number ofmaterials can be prepared from said monomers; the followingcompositional ranges are of particular interest [where e, f, g and hdenote the molar proportions of said units (IX), (X), (XI) and (XII),respectively]:

(I) those wherein n=1; e is approximately equal to f+g; f is in therange of from about 0.05 to about 0.76; g is in the range of from about0.95 to about 0.24; h is in the range of from about 0.10 to about 9.0,based on the total number of moles of monomer corresponding to units(IX); and

(II) those wherein n is 1 and 2, i.e., which are based on hydroquinoneand 4,4'-biphenol as the dihydric phenol component; the total number ofmoles of hydroquinone and 4,4'-biphenol (e") is approximately equal tothe total number of moles of terephthalic and isophthalic acids (f+g);the ratio of f to g is in the range of about 0.42:1 to about 10:1; themolar ratio of hydroquinone to 4,4'-biphenol is from about 3:1 to about99:1; and the ratio of h to f and g is 0.15:1 to 8:1.

The second wholly aromatic polyester optionally has in its chain anaphthalene-based monomer. There are of course a great number ofmaterials that meet this requirement. Especially preferred, however, arethe copolyesters which are disclosed in U.S. Pat. Nos. 4,161,470;4,184,996; and 4,256,624, herein incorporated by reference.

The polyester disclosed in U.S. Pat. No. 4,161,470 is a melt processiblewholly aromatic polyester which is capable of forming an anisotropicmelt phase at a temperature below approximately 350° C. apart from theblend. The polyester consists essentially of the recurring moieties(XIX) and (XX) which may include substitution of at least some of thehydrogen atoms present upon an aromatic ring: ##STR15## with saidoptional substitution if present being selected from the groupconsisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of1 to 4 carbon atoms, halogen, and mixtures of the foregoing. The whollyaromatic polyester there disclosed comprises approximately 10 to 90 molepercent of moiety (XIX) and approximately 90 to 10 mole percent ofmoiety (XX).

The polyester disclosed in U.S. Pat. No. 4,184,996 is a melt processiblewholly aromatic polyester which is capable of forming an anisotropicmelt phase at a temperature below approximately 325° C. apart from theblend. The polyester consists essentially of the recurring moieties(XX), (XXI), and (XXII): ##STR16##

The wholly aromatic polyester there disclosed comprises approximately 30to 70 mole percent of moiety (XX). The polyester preferably comprisesapproximately 40 to 60 mole percent of moiety (XX); approximately 20 to30 mole percent of moiety (XXI); and approximately 20 to 30 mole percentof moiety (XXII). Each of the moieties of the polyester is free of ringsubstitution.

The polyester disclosed in U.S. Pat. No. 4,256,624 is a melt processiblewholly aromatic polyester capable of forming an anisotropic melt phaseat a temperature below approximately 400° C. apart from the blend. Thepolyester consists essentially of the recurring moieties (XIX), (XXIII)and (XXIV) which may include substitution of at least some of thehydrogen atoms present upon an aromatic ring: ##STR17## wherein Ar is aspreviously defined; with said optional substitution, if present, beingselected from the group consisting of an alkyl group of 1 to 4 carbonatoms, an alkoxy group of 1 to 4 carbon atoms, halogen, a phenyl groupand mixtures of the foregoing. The polyester comprises approximately 10to 90 mole percent of moiety (XIX), approximately 5 to 45 mole percentof moiety (XXIII), and approximately 5 to 45 mole percent of moiety(XXIV).

The phenomenon of blistering is known. Blisters may occur near a surfaceor in the bulk of the sample. Here, we are mainly concerned with surfaceblisters; note, however, that small internal blisters or voids may alsobe detrimental to material performance.

Moldings based on polymers that show orientation in the melt displayskin-core effects. Hence, phenomena observed in these systems are oftenanalogous to those encountered in coatings and composites. Incomposites, for example, blistering and delamination occur especiallybetween two layers of different composition. In coatings, blistering isknown to be a localized delamination at an interface; it depends on thediffusion of chemicals such as water and degradation by-products. Thedifference in the thermal expansion coefficient between a coating andthe substrate can create stresses and may weaken the interface. Ablister may then form with less pressure difference, due to volatiles,than in cases where these stresses are absent.

In summary thus, blistering is due to a surface layer delamination andcan be caused either by trapped volatiles or by built-in stresses. Mostprobably both factors are at work.

Two types of blistering are encountered with polymeric materials: (1)molding blisters and (2) oven blisters. Blisters which occur duringmolding generally indicate the presence of degraded material. Quiteoften parts having acceptable surface characteristics are obtained uponmolding. However, when these parts are treated at high temperatures fora certain period of time, blisters ("oven blisters") often appear. Thesedo not necessarily indicate the presence of degraded material as aresult of molding.

It is of paramount importance that molding of the polymer does not yieldparts having a blistered surface. It should be noted that theconfiguration of a part is also quite often a factor in mold blistering.In any event, if molding blisters are detected upon visual examination,the part will generally blister to a considerably greater extent whenexposed to heat treatment. Thus, the particular molding compound is mostprobably of inadequate quality. If, on the other hand, a good lookingmolding part is obtained, there is no assurance as to what the resultsof "oven testing" will be. For high temperature applications, it isimperative that oven blistering be also either absent or significantlyminimized. The oven test and the method of blister rating are describedin the Experimental.

The blends of the instant invention show a considerably decreasedtendency to blister--both during molding and in the oven test.

Molding compounds and articles may be made from the subject copolyestersand blends by incorporating therein fillers and/or reinforcing agents.One attractive application of the novel copolyesters of the instantinvention is, for example, in electrical equipment and electroniccomponents. Composites as disclosed by Duska et al., U.S. Pat. No.4,626,557 are useful in this application. Molding compounds of interestin ovenware are described in commonly assigned U.S. Patent applicationentitled "Novel Plastic Ovenware Compositions," Ser. No. 255,753.Articles may also be molded from a molding compound which includes, asone component, the polymer or blends of the present invention. Such amolding compound incorporates into the present invention approximately 1to 70 percent, preferably approximately 10 to 55 percent, by weight,based upon the total weight of the molding compound, of a solid fillerand/or reinforcing agent. Representative agents which may serve asreinforcing media and fillers include glass fibers, glass beads,asbestos, graphitic carbon fibers, amorphous carbon fibers, syntheticpolymeric fibers, aluminum fibers, aluminum silicate fibers, oxide ofaluminum fibers, titanium fibers, magnesium fibers, rock wool fibers,steel fibers, tungsten fibers, cotton, wool and wood cellulose fibers,etc., glass beads, calcium silicate, silica, clays, talc, mica, carbonblack, titanium dioxide, wollastonite, polytetrafluoroethylene,graphite, alumina trihydrate, sodium aluminum carbonate, barium ferrite,etc. The molding compounds are useful in a variety of applicationsincluding high temperature applications, for example, in cookware andelectrical articles, and the like.

The novel plastic compositions of the present invention can befabricated into permanent ovenware capable of repeated use inconventional thermal and microwave ovens.

It has been found in accordance with this invention that a uniform andpleasing appearance can be imparted to ovenware articles and anyundesirable bubbling can be suppressed or minimized by the inclusion oftalc in the oxybenzoyl compositions from which they are molded. The talccontains a minimum amount of materials decomposable at elevatedtemperatures, e.g., up to about 800° C., such as magnesium carbonate.Among such talcs are talcs which are of high purity, are selectivelycombined from various ores or have been calcined or subjected to acidtreatment.

These talcs which are employed according to the present invention arecharacterized by a low weight loss on ignition, a low iron contentanalyzed as iron oxide, and a closely controlled particle size.

The weight loss on ignition of the suitable talcs is not more than 6percent or less at 950° C. and is 2 percent or less at 800° C. The ironcontent analyzed as iron oxide (Fe₂ O₃) will not be more than about 1percent and that of the particularly preferred talcs will not be morethan about 0.6 percent and may be less. In addition, the particle sizedistribution of the talc must preferably be such that about 90 to 95percent of the particles are less that about 40 microns.

Experiments and tests carried out have demonstrated quite conclusivelythat it is essential to use such talc. The use of other forms of talcdoes not provide satisfactory properties in the finished moldingproduct. However, such other forms of talc can be employed inconjunction with the specified talcs in amounts of from about 0.05percent to about 20 percent of the required forms of talc.

The talcs containing the minimum amounts of decomposable material willbe present in amounts of from about 1 percent to about 60 percent basedon the total composition weight with the preferred range being fromabout 35 percent to about 55 percent.

Rutile titanium dioxide can also be employed in conjunction with thetalc material, including mixtures of highly refined talcs and othertalc. The rutile titanium dioxide will be present in a proportion offrom about 2 percent to about 20 percent based on the weight of thetotal composition. The preferred range is from about 3 percent to about15 percent.

In the ovenware articles of the present invention, the resin willgenerally comprise from about 30 percent to about 85 percent and thetotal inerts from about 70 percent to about 15 percent. For optimumresults, the inerts will comprise from about 40 percent to about 55percent of the molding compositions. The inerts will comprise up toabout 55 percent of highly refined talc and from about 0 to about 15percent of titanium dioxide.

The compositions of the present invention can be prepared by extrusionin accordance with generally known practice. For example, a twin screwextruder can be employed with addition of the polymer, selected talc,and titanium dioxide at the feed throat and with addition of the glassroving at both the vent and feed throat.

The compositions so prepared can then be injection molded according togeneral practice using techniques familiar to the injection moldingfield.

EXAMPLES

The following examples serve to give specific illustrations of thepractice of this invention but they are not intended in any way to limitthe scope of this invention. The examples and comparative examples areplotted on the triangular phase diagram.

Experimental Procedures

The following procedures were used to obtain the data given in theexamples.

A. X-ray Measurements 1. Apparatus

X-ray diffraction data were obtained using a Philips XRG-3000 X-raygenerator equipped with a vertical diffractometer, a long, fine-focuscopper X-ray tube, a Paar HTK-10 high temperature diffractometerattachment and a Paar HTK-heat controller. Diffractometer position iscontrolled by computer, which also measures and records radiation countrate produced by sample crystallinity, and sample temperature.

(a) Determination of the Polymer Melting Point

A sample of the polymer is submitted to a preliminary X-ray diffractionscan between 15 and 25 degrees two-theta angle by increasing thetemperature by increments of 60° C. within a temperature range fromabout 200° to about 480° C. This allows determination of the approximatetemperature at which the peak located at approximately 19.7 degreestwo-theta (4.50 Å d-spacing) reaches its minimum value, i.e., anapproximate melting point. A second-degree polynomial equation isderived from the above data; this polynomial equation now allows tofollow the peak angle as the sample temperature is varied. Thetemperature at which the peak height reaches a minimum (i.e., touchesthe baseline), is considered to be the melting point. The polymer sampleis now heated and cooled at a rate of 100° C. per minute between thepreviously mentioned temperature limits, and its melting point isdetermined. Since the melting point of a crystalline material oftenchanges on heating and cooling (due to recrystallization, furtherpolymerization, etc.), the sample is cooled and reheated. This allowsdetermination of the melting point on the second heating cycle.Generally, the second cycle yields a melting point which remainsapproximately constant if additional heating or cooling cycles areperformed. Therefore, the value obtained in the second heating cycle istaken as the polymer melting point.

(b) Crystallization Temperature (Onset of Crystallization)

The onset of crystallization is measured in the same manner except thatthe scanning (for details, see above), is performed while the sample iscooled at 100° C. per minute. The temperature at which the peak emergesfrom the baseline during the second cooling cycle is considered as theonset of crystallization.

(c) Crystallization Rate

At every temperature below the sample melting point, the intensity ofX-ray diffraction of a crystalline material can be expressed as countsper second (or any unit of time). The increase in the number of countsper unit of time while the sample is being cooled at a certain rate(100° C. per minute) is therefore proportional to the rate ofcrystallization. A temperature interval starting at the onset ofcrystallization and 40° C. below that temperature was arbitrarilychosen. Rates of crystallization are expressed as the increase in countsper minute for a sample cooled within these temperature limits duringthe second cooling cycle.

B. DMA Flexural Modulus

The measurement is performed using a Dupont Dynamic Mechanical Analyzer(DMA), Model 982 in conjunction with a thermal analyzer, Model 1090. TheDMA measures changes in the viscoelastic properties of materials as afunction of time and temperature. Tests are conducted at a heating rateof 5° C. per minute. When the run is complete, the stored data isanalyzed; the storage modulus (very similar to the flexural modulus) andthe loss modulus are calculated and plotted as a function oftemperature. The modulus is expressed in GPa's and the temperature indegrees Centigrade. Conversion into psi's is performed using theequation:

    Modulus (psi)=Modulus (GPa)×(1.45×10.sup.5)

C. Compressive Flow (CF)

The term "Compressive Flow" (CF) as used in this application is ameasure of the flow of a weighed sample when pressed on a Carver pressat 5,000 pounds. It is also an indirect measure of the polymer molecularweight; the higher the CF value at a given temperature, the lower is themolecular weight of the wholly aromatic polyester.

CF is measured from the area of a disc obtained from a sample ofpowdered material of given weight, usually 0.5 to 1.0 grams which hasbeen pressed between two parallel plates. In carrying out thedetermination of this characteristic, a sample is pressed between twosheets of aluminum foil which in turn are backed by chromium-platedsteel plates 6"×6"×1/4". A Carver 2112-X Model No. 150-C hydraulic pressmodified for 800° F. is used to press the sample. The particulartemperature of the press is that indicated in each sample run. Thesample material is allowed to stand for 5 minutes between the plates atholding pressure in order that the temperature of the material canequilibrate with the press temperature. A load of 5,000 pounds is thenapplied for 2 minutes. The CF is then calculated on the following basis.The area of the pressed molding compound is measured by cutting analuminum sandwich out of the sample pressed between the two aluminumfoil sheets. The aluminum foil has a known area/weight relationshipcalled the foil factor. The area is normalized for the pressure of theapplied load and that number is multiplied by 100 to give a numbergreater than 1. The compressive flow is then calculated by means of thefollowing equation: ##EQU2##

D. Blister Rating

Samples to be tested are preconditioned at 20° to 25° C., 50±5 percentrelative humidity for 48 hours. Test sample lot normally includes fivetensile bars (1/8" thick), five HDT bars (5"×1/2"×1/4" thick) and fiveflex bars (5"×1/2"×1/8" thick). The samples are carefully inspected andany existing cracks and/or blisters are circled. The samples are thenannealed in an oven which has been equilibrated at 232° C. (450° F.) fora period of 4 hours. They are then removed, cooled and inspected. Ratingcodes follow:

0--no new blisters;

1--very slight blistering (one or two very small blisters)

2--slight blistering (three to six small blisters);

3--moderate blistering (a few large blisters and/or many small blisters;and

4--heavy blistering (many large or small blisters covering more thanhalf of of the specimen surface.

The numerical blister rating is calculated using the equation: ##EQU3##where R=numerical blister rating (0-16); n=number of samples tested;X_(i) =blister rating sample i (0-4).

In the above calculation, the individual ratings for the entire set oftest samples (tensile bars, HDT bars, flex bars) are generally treatedas a single population. The ratings vary within the range of 0 (noblistering) to 16 (severe blistering, worst case).

E. Determination of the Fiber Rating

Fiber ratings were obtained using a hot bar apparatus with a temperaturerange from 270° to 415° C. A 2 to 5 gram sample of polymer is thinly andevenly sprinkled on the upper portion of the hot bar using a spatula andis allowed to melt. Using a large pair of tweezers, grab a small portionof material from the melted pool and slowly draw a fiber at a steadyspeed. The following rating system is used:

0--Material does not melt or does not draw a fiber

1--Material draws a short fiber with poor strength

2--Material draws an intermediate length fiber with intermediate levelof tenacity or material draws a long fiber with poor strength

3--Material draws a long fiber with good strength

L--An additional rating of L is added to the rating of 0-3 if a low melttemperature occurs which indicates low molecular weight

A--An additional rating of A is added if the melted material is clearwhich indicates the material is amorphous in the melt state

F. VPS

VPS or vapor phase soldering is an assembly technique used to soldercomponents to a printed circuit board. This technique involves heating afluid to its boiling point so that a vapor is produced that is above themelting temperature of standard solder. The printed circuit assembly isplaced into the vapor blanket. The vapor condenses onto the printedcircuit assembly and causes the solder to reflow.

VPS Procedure

1. Samples were processed as received and preconditioned for 7-dayintervals at 75% Relative Humidity/Room Temperature.

2. The vapor phase unit used was Model No. 912 II manufactured by HTC.

3. The primary vapor was FC-70 Fluorinert, an inert fluorochemicalmanufactured by 3M Company. The vapor was at a temperature of 428° F.(220° C.).

4. The secondary vapor was Genesolv D, a trichlortrifluoroethanemanufactured by Allied Chemical Company. The vapor was maintained at atemperature of approximately 117° F. (47° C.).

5. The samples were lowered through the secondary vapor into the primaryvapor and allowed to dwell for 4 minutes.

6. During the removal cycle, the samples were allowed to dwell for 30seconds in the Genesolv D vapor and then removed totally.

7. Samples were examined for blistering. If no blistering is evident,then the samples are considered passed. If blisters are evident, thesample has failed.

G. Miscellaneous

The flexural strength of the experimental samples was measured accordingto the procedure of ASTM D-790-84A; and HDT (DTUL) data were obtainedusing the method as described in ASTM D648. Tensile strength weremeasured in accord with ASTM D-638

Polymerizations Example P-1

This is an example of the synthesis of a novel polyester based onterephthalic acid, isophthalic acid, p-hydroxybenzoic acid, andhydroquinone in the nominal mole ratio of 0.6:0.4:0.5:1. The followingingredients were combined in the manner described.

    ______________________________________                                        Item  Ingredient            Amount                                            ______________________________________                                        A     Terephthalic acid     5.311   kg                                        B     Isophthalic acid      3.541   kg                                        C     p-Hydroxybenzoic acid 3.680   kg                                        D     Hydroquinone          5.868   kg                                        E     Acetic anhydride      15.645  g                                         F     Magnesium acetate tetrahydrate                                                                      0.46    g                                         G     Triphenyl phosphite   7.36    g                                         ______________________________________                                    

Items A through F were charged to a 15-gallon, oil heated vesselequipped with an anchor type stirrer, reflux condenser, after condenser,injection port, and distillate receiver. After purging with nitrogen,the contents were heated with stirring to 141° C. and held under refluxat that temperature for 3 hours. Distillation was then started whileincreasing the temperature over a 4.8 hour period to 285° C. Item G wasthen injected into the vessel. After an additional 15 minutes thecontents of the vessel were transferred to a sigma blade mixer that hadbeen preheated to 320° C. After mixing for 4 hours at this temperatureunder an atmosphere of nitrogen, the mixer was cooled to near roomtemperature where the contents were removed as a granular solid.

The melting point of the polymer (X-ray) was 359° C.; itscrystallization temperature was 336° C. with a crystallization rate of2,400.

A sample of the polymer was melted, extruded and pelletized with a twinscrew extruder. The pellets were molded into test specimens. Theresulting testing showed superior high temperature performance with aheat distortion temperature of 250° C. and a flexural modulus of 570,000psi as measured at 250° C. by DMA.

A molding composition containing 70 weight percent of the above polymerand 30 weight percent of milled glass fiber was prepared by compoundingon a twin screw extruder and molded into test specimens. The heatdistortion temperature of the obtained composite was 264° C. and itsflexural modulus (by DMA) was 520,000 psi as measured at 250° C.(ASTM-D-4065)

Example P-2

The ingredients were the same as in Example P-1 with the exception thatthe amount of item F was 14.16 grams, and that item G was not used inthe preparation. The equipment was the same as in example 1 and theoperating procedure is described below.

After purging with nitrogen, the contents were heated with stirring to141° C. and held under reflux at that temperature for 3 hours.Distillation was then started with increasing the temperature over a 3.6hour period to 250° C. The reaction mixture was then stirred for 1 hourat 250°-260° C.

The contents of the vessel were transferred to a sigma blade mixer whichhad been preheated to about 250° C. The material was mixed while thetemperature was increased to 300° C. and mixing was continued for atotal of 5 hours at that temperature.

A molding composition containing 70 weight percent of the above polymerand 30 weight percent of milled glass fiber was prepared by compoundingon a twin screw extruder and molded into test specimens. The heatdistortion temperature of the obtained composite was 250° C. and itsflexural modulus (by DMA) was 420,000 psi as measured at 250° C.(ASTM-D-4065)

Example P-3

The ingredients were the same as in Example P-2 with the exception ofitem F the amount of which was 7.08 grams; also, 16.00 grams oftriphenyl phosphite were added prior to transfer of the reaction mixtureto the sigma blade mixer. Otherwise, the procedure was the same as inExample P-2.

The melting point of the polymer (X-ray) was 359° C.; itscrystallization temperature was 329° C. with a crystallization rate of2,500.

A molding composition containing 70 weight percent of the above polymerand 30 weight percent of milled glass fiber was prepared by compoundingon a twin screw extruder and molded into test specimens. The heatdistortion temperature of the obtained composite was 268° C. and itsflexural modulus (by DMA) was 480,000 psi as measured at 250° C.(ASTM-D-4065)

Example P-4

This is an example of the synthesis of a novel polyester based onterephthalic acid, isophthalic acid, p-hydroxybenzoic acid andhydroquinone in the nominal mole ratio of 0.6:0.4:0.75:1. The followingingredients were combined in the manner described:

    ______________________________________                                        Item  Ingredient            Amount                                            ______________________________________                                        A     Terephthalic acid     4.829   kg                                        B     Isophthalic acid      3.219   kg                                        C     p-Hydroxybenzoic acid 5.018   kg                                        D     Hydroquinone          5.334   kg                                        E     Acetic anhydride      15.645  kg                                        F     Magnesium acetate tetrahydrate                                                                      0.46    g                                         G     Triphenyl phosphite   7.36    g                                         ______________________________________                                    

These ingredients were processed as described in Example P-1.

The melting point of the polymer (X-ray) was 353° C.; itscrystallization temperature was 331° C. with a crystallization rate of2,100.

A molding composition containing 70 weight percent of the above polymerand 30 weight percent of milled glass fiber was prepared by compoundingon a twin screw extruder and molded into test specimens. The heatdistortion temperature of the obtained composite was 240° C.

Example P-5

This is an example of the synthesis of a novel polyester based onterephthalic acid, isophthalic acid, p hydroxybenzoic acid, andhydroquinone in the nominal mole ratio of 0.4142/0.5858/0.4285/1.015.The following ingredients were combined in the manner described.

    ______________________________________                                        Item  Ingredient            Amount                                            ______________________________________                                        A     Terephthalic acid     3.761   kg                                        B     Isophthalic acid      5.319   kg                                        C     p-Hydroxybenzoic acid 3.235   kg                                        D     Hydroquinone          6.108   kg                                        E     Acetic anhydride      15.776  g                                         F     Magnesium acetate tetrahydrate                                                                      7.06    g                                         G     Triphenyl phosphite   16.00   g                                         ______________________________________                                    

Items A through F were charged to a 15-gallon, oil heated vesselequipped with an anchor type stirrer, reflux condenser, after condenser,injection port, and distillate receiver. After purging with nitrogen,the contents were heated with stirring to 141° C. and held under refluxat that temperature for 3 hours. Distillation was then started whileincreasing the temperature 20° C./hr to 259° C. Item G was then injectedinto the vessel. After the reactor reached 263° C. the contents of thevessel were transferred to a sigma blade mixer that had been preheatedto 300° C. After mixing for 5 hours at this temperature under anatmosphere of nitrogen, the mixer was cooled to near room temperaturewhere the contents were removed as a granular solid.

The melting point of the polymer (X-ray) was 268° C.; itscrystallization temperature was 248° C. with a crystallization rate of186.

A sample of the polymer was blended with glass, melted, extruded andpelletized with a twin screw extruder. The pellets were molded into testspecimens. The resulting testing showed superior high temperatureperformance with a heat distortion temperature of 238° C., and with ablister rating of 2.0, a flex strength of 19,780, and a flex modulus of1.88×10⁶.

Additional polymers were examined in Tables I-IV. The polymers of thetables were prepared using the mole percentage of monomers delineated inthe table and reacting them in the same manner as P-1.

Comparative Example 1

This example describes the preparation of a polyester in the laboratory.It is to be noted that the preferred method as described in ComparativeExample 2 wherein the polymers were produced in scaled up size in thepilot plant. There a continuous method of in situ polymerization wasutilized which is more demonstrative of scale-up production andeconomies. Unfortunately in scale-up production, physical and mechanicalcharacteristics can be varied as compared to laboratory production. Thepolyester had the molar composition: terephthalic acid/isophthalicacid/p-hydroxybenzoic acid/hydroquinone 0.5/0.5/1.0/1.0 (see Cottis etal., U.S. Pat. No. 3,637,595; example no. 10, noted as designation "x"on FIG. 1). The properties of this polymer do not meet the requirementsof the polyesters of the instant invention.

A 5 liter resin flask equipped with a stirrer, condenser system designedboth for reflux and distillation, and a heating mantle was charged withthe following:

1,092.5 g of p-hydroxybenzoic acid;

657.1 g of terephthalic acid;

657.1 g of isophthalic acid;

871.0 g of hydroquinone; and

2,786.0 g of acetic anhydride.

The above mixture was heated at reflux for a period of 3 hours; vigorousstirring was maintained throughout the reaction. At the end of thereflux period collection of distillate was started. The reaction masswas then heated at a rate of about 30° C. per hour to 311° C. at whichpoint 98.2 percent of the theoretical distillate was collected. Themolten material was poured into an aluminum pan and allowed to cool toroom temperature. The solid was pulverized and ground to pass a 2millimeter screen. The powder was placed in a drum and was heated in anitrogen stream, while rotating, to a temperature of 330° C.; and heldat that temperature for two hours. The product was removed from the drumafter cooling.

The melting point of the polymer (X-ray) was 325° C.; itscrystallization temperature (onset of crystallization) andcrystallization rate (both measured via X-ray techniques) were 299° C.and 2,242, respectively.

A portion of the product was pelletized and injection molded into testspecimens. The neat polymer had a HDT of 226° C.; a flex strength of16,000; a modulus 1.85×10⁶ ; and a blister rating of 16.

Another portion of the product was compounded with milled glass fiber toprepare a pelletized material containing 30 percent glass. Injectionmolding yielded test specimens which were very brittle. Therefore, torun HDT analyses, 1/8" Flex Bars were used. The HDT was 233° C.

Comparative Example 2

This example describes the preparation of a polyester having the moleratio of 0.5/0.5/1.0/1.015. The following ingredients were combined inthe manner described:

    ______________________________________                                        Item  Ingredient            Amount                                            ______________________________________                                        A     Terephthalic acid     3.678   kg                                        B     Isophthalic acid      3.678   kg                                        C     p-Hydroxybenzoic acid 6.115   kg                                        D     Hydroquinone          4.948   kg                                        E     Acetic anhydride      15.782  kg                                        F     Magnesium acetate tetrahydrate                                                                      7.06    g                                         G     Triphenyl phosphite   16.00   g                                         ______________________________________                                    

Items A through F were charged to a 15-gallon, oil heated vesselequipped with an anchor type stirrer, reflux condenser, after condenser,injection port, and distillate receiver. After purging with nitrogen,the contents were heated with stirring to 141° C. and held under refluxat that temperature for 3 hours. Distillation was then started whileincreasing the temperature 30° C./hour to 273° C. Item G was theninjected into the vessel. After the reactor reached 277° C. the contentsof the vessel were transferred to a sigma blade mixer that had beenpreheated to 285° C. After mixing for 5 hours at this temperature underan atmosphere of nitrogen, the mixer was cooled to near room temperaturewhere the contents were removed as a granular solid.

The melting point of the polymer (X-ray) was 349° C.; itscrystallization temperature was 331° C. with a crystallization rate of1667.

A sample of the polymer was blended with glass, melted, extruded, andpelletized with a twin screw extruder. The pellets were molded into testspecimens. The resulting testing showed lower temperature performancewith a 264 psi heat distortion temperature of only 214° C.

Blends Preparative Examples Example B-1

Preparation of polyester having the following molar composition: 0.25moles isophthalic acid/0.75 moles terephthalic acid/3.0 molesp-hydroxybenzoic acid/1.0 mole 4,4'-biphenol. A mixture of:

184 lbs of terephthalic acid;

61 lbs of isophthalic acid;

612 lbs of low ash p-hydroxybenzoic acid;

275 lbs of 4,4'-biphenol;

868 lbs of acetic anhydride; and

40.1 grams (88.5 ppm) of magnesium acetate tetrahydrate

was placed in a 325 gallon rector and heated with stirring untildistillation started. The rector was held at this temperature for 3hours. Distillation was started and the temperature increased until 400pounds of distillate has been collected. The contents were pressuredinto a 200 gallon reactor and the temperature was increased at a rate of30° C. per hour until the contents reached 313° C. Then the contentswere poured into a mechanical mixer and mixed at 290° to 300° C. for 5hours. Six batches of polymers were made with compressive flows at 330°C. from 55 to 74, and polymer had very good color.

Example B-2

Preparation of polyester having the following molar composition: 1 moleterephthalic acid/3.7 moles p-hydroxybenzoic acid/1 mole 4,4'-biphenol.

The following ingredients were combined in the manner described:

    ______________________________________                                        Item  Ingredient            Amount                                            ______________________________________                                        A     Terephthalic acid     1.638   kg                                        B     p-Hydroxybenzoic acid 5.039   kg                                        C     4,4'-Biphenol         1.837   kg                                        D     Acetic anhydride      6.600   kg                                        E     Potassium sulfate     0.5     g                                         F     Pentaerythritol diphosphite                                                                         6.6     g                                         ______________________________________                                    

Items A through E were charged into the rector and heated to 307° C.over a period of 10 hours with distillation of acetic acid. Item F wasthen added and heating was continued for 6 minutes to a melt temperatureof 310° C. The contents of the vessel were transferred to a sigma blademixer that had been preheated to 335° C. The temperature was raised to350° C. and mixing was continued at 350° C. for 9.5 hours under anatmosphere of nitrogen. The mixer was cooled to near room temperaturewhere the contents were removed as a granular solid having a compressiveflow of 52.

Example B-3

The naphthalene-based polyester used in the instant blends was Vectra®A950, produced by the Hoechst-Celanese Corporation and composed of about73 mole percent 4-oxybenzoyl moieties (XX) and 27 mole percent of6-oxy-2-naphthoyl moieties (XIX): ##STR18##

Preparation of Polyester Blends General

Polyesters prepared as described in preparative examples B-1 and B-2were formulated into a 30 percent glass filled composition, compoundedand pelletized. The blends contained as a percentage of the resinsphase, either 0, 10, 21 or 40 weight percent of polymer (B). Theformulations were compounded and pelletized on a 25 mm diameterBerstorff twin screw extruder. The barrel profile temperature forcompounding was:

    ______________________________________                                                Barrel zone 1 =                                                                         320 to 325° C.                                               Barrel zone 2 =                                                                         355 to 362° C.                                               Barrel zone 3 =                                                                         355 to 376° C.                                               Barrel zone 4 =                                                                         365 to 395° C.                                               Barrel zone 5 =                                                                         380 to 400° C.                                               Barrel zone 6 =                                                                         370 to 380° C.                                               Barrel zone 7 =                                                                         360 to 370° C.                                               Die =     355 to 380° C.                                       ______________________________________                                    

The screw rpm was 170 to 175; the output was 12 to 15 pounds per hour.

The above materials were molded on a 75 ton, 3 ounce Newbury injectionmolding machine. The barrel profile was:

Rear zone about 377° C.

Front zone about 382° C.

Nozzle about 388° C.

The mold temperature was set at 121° C. and the injection pressure wasin the range of 1,000 to 1,360 psi. The molding machine screw rpm wasabout 330.

The formulations of Table VII were compounded and pelletized on a 25 mmdiameter Berstorff twin screw extruder. The barrel profile temperaturefor compounding was:

    ______________________________________                                                Barrel zone 1 =                                                                         293 to 320° C.                                               Barrel zone 2 =                                                                         360 to 376° C.                                               Barrel zone 3 =                                                                         375 to 400° C.                                               Barrel zone 4 =                                                                         395 to 405° C.                                               Barrel zone 5 =                                                                         390 to 400° C.                                               Barrel zone 6 =                                                                         370 to 385° C.                                               Barrel zone 7 =                                                                         375 to 387° C.                                               Die =     370 to 387° C.                                       ______________________________________                                    

The screw rpm was 175 with an output of about 10 to 13 pounds per hour.

The above materials were molded on a 75 ton, 3 ounce Newbury injectionmolding machine having the following barrel temperature profile:

Rear zone about 377° C.

Front zone about 382° C.

Nozzle about 388° C.

The mold temperature was set at 120° C. for composition no. 7 and at 66°C. for all other compositions. The injection pressure was 1,000 psi andthe molding machine screw rpm was about 330.

    ______________________________________                                        Blends of Table XI (test nos. 21-32):                                                 Barrel zone 1 =                                                                         150 to 176° C.                                               Barrel zone 2 =                                                                         270 to 345° C.                                               Barrel zone 3 =                                                                         285 to 365° C.                                               Barrel zone 4 =                                                                         275 to 370° C.                                               Barrel zone 5 =                                                                         270 to 370° C.                                               Barrel zone 6 =                                                                         280 to 365° C.                                               Barrel zone 7 =                                                                         275 to 360° C.                                               Die =     270 to 355° C.                                       Blends of Table XI (test nos. 33-40):                                                 Barrel zone 1 =                                                                          185 to 301° C.                                              Barrel zone 2 =                                                                          370 to 385° C.                                              Barrel zone 3 =                                                                          385 to 400° C.                                              Barrel zone 4 =                                                                          390 to 400° C.                                              Barrel zone 5 =                                                                          385 to 390° C.                                              Barrel zone 6 =                                                                          375 to 380° C.                                              Barrel zone 7 =                                                                          370 to 376° C.                                              Die =      370 to 374° C.                                      Blends of Table XI (test nos. 41-44):                                                 Barrel zone 1 =                                                                          320°  C.                                                    Barrel zone 2 =                                                                          355 to 360° C.                                              Barrel zone 3 =                                                                          370 to 375° C.                                              Barrel zone 4 =                                                                          390 to 395° C.                                              Barrel zone 5 =                                                                          390° C.                                                     Barrel zone 6 =                                                                          370° C.                                                     Barrel zone 7 =                                                                          370 to 376° C.                                              Die =      350 to 375° C.                                      ______________________________________                                    

The screw rpm was in the range of 120 to 175 for all the blends; theoutput was about 10 to 13 pounds per hour.

The above materials were molded on a 75 ton 3 ounce Newbury injectionmolding machine having the following barrel temperature profile:

    ______________________________________                                        Blends of Table XI (test nos. 21-32):                                                 Rear zone =                                                                            376 to 337° C.                                                Front zone =                                                                           271 to 337° C.                                                Nozzle = 282 to 348° C.                                        Blends of Table XI (test nos. 33-40):                                                 Rear zone =                                                                            337 to 388° C.                                                Front zone =                                                                           332 to 382° C.                                                Nozzle = 343 to 393° C.                                        Blends of Table XI (test nos. 41-44):                                                 Rear zone =                                                                            299 to 371° C.                                                Front zone =                                                                           288 to 377° C.                                                Nozzle = 299 to 382° C.                                        ______________________________________                                    

The mold temperature was set at 66° C. for compositions 21 to 32 and 36;it was 99° C. for no. 44 and 120° C. in all other examples. Theinjection pressure was:

1,000 psi in examples: Table XI, 21,27,28,29,30,31,32,35,36,37 and 38;

1,400 psi in all other blend examples.

The molding machine screw rpm was set at 330.

Examinations of the table shows that the blends can generally befabricated at lower temperatures than the corresponding controls;therefore there is less chance of decomposition and concurrently lessblistering.

SUMMARY OF TABLES Tables I-V: Properties of Neat and Glass-FilledPolymers Tables I-III

Table I lists some polyesters whose properties meet the specificationsof the polymers of the instant invention as far as melting point,crystallization temperature and crystallization rate are concerned.

Table II lists other polyesters which are borderline resins, i.e., thosewhere (a) at least one of the three basic properties (melting point,crystallization temperature and crystallization rate--all as measured byX-ray techniques) is within the required range, the other two propertiesbeing outside of the range, but very close to it; or (b) where all threeproperties are in the required range, but the HDT does not satisfy therequirements and/or the material is not moldable.

Table III lists still other polymers whose properties are outside of thespecifications of this invention.

The data clearly show that well defined ratios of monomers are criticalif one wants to achieve polyesters having the outstandingcharacteristics as described in this application.

Table IV: Viscosity Analysis and Blister Rating

Region C has a lower viscosity than region A which is advantageous formolding. Blister ratings are lower hence articles have better surfacecharacteristics.

Table V: Molding Conditions of the Polymers in Table VI

To mold materials in the A or X regions it requires higher moldingtemperatures to achieve a melt phase. If a homogeneous melt phase is notachieved, a molded article will have poor mechanical properties.

Table VI: Polymers

Table VI shows other polymers derived from the monomers and %'s shownand the mechanical properties of these polymers. It depicts that the Aregion (which corresponds to the triangular diagram FIG. 1) has a higherHDT than the X region (Cottis U.S. Pat. No. 3,637,595) and also animproved blister rating, tensile strength, and % elongation. It depictsthat the C region has even better blister ratings and significantly, itpasses the VPS test.

Table VII: Polymer Fiber Rating

Table VII depicts polymers derived from the monomers and %'s as listed.It shows an improved fiber rating of the A region over the othernon-designated regions of the phase diagram. It is noteworthy thatregion C has even more favorable fiber ratings.

Tables VIII-XV: Blends of Polyesters (a) and (b) and Their Properties

Table VII discloses blends of three different polyesters. The propertiesof these blends are shown in Tables VIII-X.

Table X depicts other blends and Table XII depicts the properties ofblends of Table XI.

The blends have lower injection molding temperatures than the basepolymer showing they can be fabricated at lower temperatures. The dataclearly show that the blends display improved mechanicalproperties--see, for example, flexural strengths and blister rating ofTable VIII tests 4-6. The high HDT's of the novel blends are noteworthy;they are intermediate between those of the constituent polymers of theblends. This in turn could be interpreted as a result of compatibilityfor the instant highly crystalline polyesters. DMA modulus data showthat stiffness is maintained up to quite high temperatures, making thepresent materials useful at elevated temperatures. In conclusion,therefore, the blends of this invention possess a combination oftoughness, surface, and high temperature properties that could not beanticipated beforehand.

                  TABLE I                                                         ______________________________________                                        POLYMERS                                                                                      Properties                                                                          Melting  Cryst.                                         Example                                                                              Composition    Point    Temp. Cryst.                                   No. (a)                                                                              q       r       s    (°C.)                                                                         (°C.)                                                                        Rate (b)                             ______________________________________                                         5     0.20    0.80    5.00 340    316   2000                                  6     0.50    0.50    2.00 367    334   2473                                  7     0.50    0.50    1.25 351    315   2500                                  8     0.60    0.40    0.60 366    329   2420                                  9      0.538   0.462  0.538                                                                              341    308   1350                                 10      0.571   0.429  0.429                                                                              384    325   1636                                 11     0.60    0.40    0.333                                                                              357    330   3315                                 12     0.53    0.47    0.333                                                                              343    300   2210                                 13     0.60    0.40    0.250                                                                              393    331   1920                                 ______________________________________                                         (a) The polymers were prepared via methods similar to that used in            comparative Example 2. In all of the examples, p is one.                      (b) Counts per minute.                                                   

                                      TABLE II                                    __________________________________________________________________________    POLYMERS                                                                                      Properties                                                                    Melting                                                                            Cryst.                                                   Example                                                                            Composition.sup.(c)                                                                      Point                                                                              Temp.                                                                             Cryst.                                               No..sup.(a)                                                                        q   r   s  (°C.)                                                                       (°C.)                                                                      Rate.sup.(e)                                                                       Remarks.sup.(d)                                 __________________________________________________________________________    14   0.30                                                                              0.70                                                                              7.00                                                                             393  359 3100 --                                              15   0.20                                                                              0.80                                                                              7.00                                                                             393  359 3100 --                                              16   0.10                                                                              0.90                                                                              7.00                                                                             370  343 2600 --                                              17   0.00                                                                              1.00                                                                              7.00                                                                             353  323 2100 Poor processibility                                                           HDT = 219° C.                            18   0.40                                                                              0.60                                                                              5.00                                                                             389  352 2800 --                                              19   0.30                                                                              0.70                                                                              5.00                                                                             373  341 2700 --                                              20.sup.(b)                                                                         0.50                                                                              0.50                                                                              1.50                                                                             343  313 2500 Neat polymer fused at                                                         450° C. with decomposition                                             (smoke) when compounding                                                      was attempted.                                  21   0.60                                                                              0.40                                                                              1.25                                                                             387  347 2810 --                                              22.sup.(b)                                                                         0.60                                                                              0.40                                                                              1.00                                                                             361  335 2700 Same as Example 20                              23   0.50                                                                              0.50                                                                              1.00                                                                             334  300 1794 --                                              24   0.60                                                                              0.40                                                                              1.00                                                                             389  341 3200 --                                              25   0.50                                                                              0.50                                                                              0.75                                                                             362  291 2000 --                                              26   0.55                                                                              0.45                                                                              0.60                                                                             333  311 1510 --                                              27    0.615                                                                             0.385                                                                            0.538                                                                            381  344 3860 --                                              28    0.643                                                                             0.357                                                                            0.429                                                                            400  351 2500 --                                              29   0.50                                                                              0.50                                                                              0.429                                                                            334  294 2110 --                                              30   0.47                                                                              0.53                                                                              0.333                                                                            366  304  820 --                                              31   0.00                                                                              1.00                                                                              0.10                                                                             387  309  430 --                                              __________________________________________________________________________     .sup.(a) Prepared in a manner similar to that of comparative Example 1,       except where otherwise indicated.                                             .sup.(b) Prepared in a manner similar to that of Example P1.                  .sup.(c) In all examples p is equal to one.                                   .sup.(d) HDT measured on 30 percent by weight milled glass filled             compositions.                                                                 .sup.(e) Counts per minute.                                              

                                      TABLE III                                   __________________________________________________________________________                    Properties                                                                     Melting                                                                            Cryst.                                                  Example                                                                            Composition.sup.(c)                                                                       Point                                                                              Temp.                                                                             Cryst.                                              No..sup.(a)                                                                        q   r   s   (°C.)                                                                       (°C.)                                                                      Rate.sup.(f)                                                                       Remarks.sup.(d)                                __________________________________________________________________________    32   1.00                                                                              0.00                                                                              7.00                                                                              486  445 4200 Could not compound or mold.                    33   0.80                                                                              0.20                                                                              7.00                                                                              433  413 4706 --                                             34   0.70                                                                              0.30                                                                              7.00                                                                              453  410 5400 --                                             35   0.60                                                                              0.40                                                                              7.00                                                                              437  399 5100 --                                             36   0.50                                                                              0.50                                                                              7.00                                                                              428  389 4800 --                                             37   0.40                                                                              0.60                                                                              7.00                                                                              419  380 4200 --                                             38   1.00                                                                              0.00                                                                              5.00                                                                              497  456 4700 Could not compound or mold.                    39   0.80                                                                              0.20                                                                              5.00                                                                              460  427 4600 --                                             40   0.70                                                                              0.30                                                                              5.00                                                                              443  403 4200 --                                             41   0.60                                                                              0.40                                                                              5.00                                                                              448  388 4500 --                                             42   0.50                                                                              0.50                                                                              5.00                                                                              413  376 3200 --                                             .sup.   43.sup.(b)                                                                 0.35                                                                              0.65                                                                              5.00                                                                              --   --  --   Heavy smoke and decomposition                                                 during extrusion                               44   0.10                                                                              0.90                                                                              5.00                                                                              324  300 2200 --                                             45   0.00                                                                              1.00                                                                              5.00                                                                              298  296  310 --                                             46   1.00                                                                              0.00                                                                              4.00                                                                              492  458 3300 --                                             47   1.00                                                                              0.00                                                                              3.00                                                                              497  460 3500 Could not compound or mold.                    48   0.90                                                                              0.10                                                                              3.00                                                                              492  452 6740 --                                             49   0.80                                                                              0.20                                                                              3.00                                                                              468  431 6410 --                                             50   0.70                                                                              0.30                                                                              3.00                                                                              446  406 6620 --                                             51   0.60                                                                              0.40                                                                              3.00                                                                              369  408 4550 --                                             52   0.00                                                                              1.00                                                                              3.00                                                                              204  204  617 Processing marginal;                                                          HDT = 175° C..sup.(d).                  53   0.00                                                                              1.00                                                                              2.50                                                                              Weak Weak                                                                              Weak Processing adequate;                                                          HDT = 163° C..sup.(d).                  54   1.00                                                                              0.00                                                                              2.00                                                                              520  481 6700 Could not compound or mold.                    55   0.70                                                                              0.30                                                                              2.00                                                                              415  398 5000 --                                             56   0.60                                                                              0.40                                                                              2.00                                                                              405  368 5066 --                                             57   0.40                                                                              0.60                                                                              2.00                                                                              329  300 1789 --                                             58   0.30                                                                              0.70                                                                              2.00                                                                              299  269 1368 --                                             59   0.20                                                                              0.80                                                                              2.00                                                                              300  248  842 --                                             60   0.00                                                                              1.00                                                                              2.00                                                                              Weak Weak                                                                              Weak Processing adequate;                                                          HDT = 175° C..sup.(d).                  61   0.00                                                                              1.00                                                                              1.75                                                                              400  368 208  Processing adequate;                                                          HDT = 142° C..sup.(d).                  .sup.   62.sup.(b)                                                                 0.75                                                                              0.25                                                                              1.50                                                                              440  404 4200 Decomposed; did not melt.                      .sup.   63.sup.(b)                                                                 0.67                                                                              0.33                                                                              1.50                                                                              413  377 4200 Neat polymer fused at 450° C.                                          w/decomposition (smoke) when                                                  compounding was attempted.                     64   0.60                                                                              0.40                                                                              1.50                                                                              387  353 2500 As above                                       65   0.40                                                                              0.60                                                                              1.50                                                                              289  279  962 --                                             66   0.30                                                                              0.70                                                                              1.50                                                                              249  240  850 Processing marginal;                                                          HDT = 218° C..sup.(e).                  67   0.20                                                                              0.80                                                                              1.50                                                                              231  223  490 --                                             68   0.10                                                                              0.90                                                                              1.50                                                                              Weak Weak                                                                              Weak --                                             69   0.00                                                                              1.00                                                                              1.50                                                                              --   --  --   Processing adequate;                                                          HDT = 187° C..sup.(e).                  70   0.70                                                                              0.30                                                                              1.25                                                                              428  392 6068 --                                             71   0.40                                                                              0.60                                                                              1.25                                                                              304  272 1375 --                                             72   0.30                                                                              0.70                                                                              1.25                                                                              267  260  588 --                                             73   1.00                                                                              0.00                                                                              1.00                                                                              523  490 2700 Could not be compounded or molded.             74   0.80                                                                              0.20                                                                              1.00                                                                              466  432 4100 --                                             75   0.70                                                                              0.30                                                                              1.00                                                                              440  392 2000 --                                             76   0.40                                                                              0.60                                                                              1.00                                                                              256  251  900 --                                             77   0.30                                                                              0.70                                                                              1.00                                                                              235  235  350 --                                             78   0.20                                                                              0.80                                                                              1.00                                                                              Weak Weak                                                                              Weak --                                             79   0.10                                                                              0.90                                                                              1.00                                                                              Weak Weak                                                                              Weak --                                             80   0.00                                                                              1.00                                                                              1.00                                                                              Weak Weak                                                                              Weak --                                             81   0.80                                                                              0.20                                                                              0.75                                                                              464  430 6820 --                                             82   0.70                                                                              0.30                                                                              0.75                                                                              421  382 5000 --                                             83   0.40                                                                              0.60                                                                              0.75                                                                              298  272  580 --                                             84   0.20                                                                              0.80                                                                              0.75                                                                              342  Weak                                                                              Weak --                                             85   0.00                                                                              1.00                                                                              0.75                                                                              334  334  160 --                                             86    0.462                                                                             0.538                                                                             0.538                                                                            339  290  763 --                                             87   1.00                                                                              0.00                                                                              0.50                                                                              592  534 3420 --                                             88   0.30                                                                              0.70                                                                              0.50                                                                              391  391  69  --                                             89   0.00                                                                              1.00                                                                              0.50                                                                              376  285  150 --                                             90   0.80                                                                              0.20                                                                              0.25                                                                              471  438 4300 --                                             91   0.70                                                                              0.30                                                                              0.25                                                                              421  370 3100 --                                             92   0.50                                                                              0.50                                                                              0.25                                                                              425  317  100 --                                             93   0.30                                                                              0.70                                                                              0.25                                                                              374  325  71  --                                             94   0.00                                                                              1.00                                                                              0.25                                                                              354  243  113 --                                             95   0.61                                                                              0.39                                                                              0.22                                                                              420  343 1292 --                                             96   0.41                                                                              0.59                                                                              0.18                                                                              420  Weak                                                                              Weak --                                             97   0.70                                                                              0.30                                                                              0.10                                                                              432  396 2090 --                                             98   0.50                                                                              0.50                                                                              0.10                                                                              400  350  600 --                                             99   0.30                                                                              0.70                                                                              0.10                                                                              Weak Weak                                                                              Weak --                                             100  0.80                                                                              0.20                                                                              0.00                                                                              531  525 3400 --                                             101  0.70                                                                              0.30                                                                              0.00                                                                              540  504 4300 --                                             102  0.10                                                                              0.90                                                                              0.00                                                                              402  338  120 --                                             __________________________________________________________________________     .sup.(a) Polymers were prepared in a manner similar to that of Comparativ     Example 1, except where noted.                                                .sup.(b) Prepared as described in Example P1.                                 .sup.(c) In all Examples p is equal to 1.                                     .sup.(d) Measured on a 37 weight percent talc filled composition.             .sup.(e) Measured on a 30 weight percent milled glass filled composition.     .sup.(f) Counts per minute.                                              

                  TABLE IV                                                        ______________________________________                                        VISCOSITY ANALYSIS BY SIEGLAFF-MCKELVEY                                       CAPILLARY RHEOMETRY                                                                                      Viscosity                                          Monomers                   Poise at  Blister                                  Region q      r      s     Temp (°C.)                                                                     100 Sec..sup.-1                                                                       Rating                             ______________________________________                                        A      0.6    0.4    0.5   400     88701   16.0                               A      0.6    0.4    0.5   410     8892    16.0                               C      0.414  0.586  0.4285                                                                              360     3724    2.2                                C      0.414  0.586  0.4285                                                                              370     2268    2.2                                C      0.414  0.586  0.4285                                                                              390     1489    2.2                                C      0.414  0.586  0.4285*                                                                             390     3083    2.0                                A      0.5    0.5    0.4285                                                                              360     4345    8.0                                A, C   0.5    0.5    0.4285*                                                                             360     7534    9.6                                Control                                                                              XYDAR*        360       1081    0.0                                           Polymer produced                                                              by Amoco                                                                      Performance                                                                   Products, Inc.                                                         ______________________________________                                         *Compounded with 30% glass                                               

                  TABLE V                                                         ______________________________________                                        MOLDING CONDITIONS                                                            Barrel Temps (°F.)    Mold                                             No.  Zone 3    Zone 2  Nozzle  RPM   Temp (°C.)                        ______________________________________                                         1   670       610     690     250   120                                       2   690       700     710     250   120                                       3   715       705     725     330   120                                       4   695       685     705     330   120                                       5   695       685     705     330   120                                       6   695       685     705     330   120                                       7   695       685     705     330   120                                       8   695       685     705     330   120                                       9   710       700     720     330   120                                      10   720       710     730     330   120                                      11   750       740     760     330   120                                      12   750       740     760     330   120                                      13   780       780     790     330   120                                      14   780       780     790     330   120                                      15   705       725     715     250   120                                      16   680       700     690     250   120                                      17   680       700     690     250   120                                      18   705       725     715     250   120                                      19   720       710     730     330   120                                      20   720       710     730     330   120                                      21   690       710     660     250   120                                      22   710       720     700     250   120                                      23   710       700     720     330   120                                      24   710       700     720     330   120                                      25   700       700     710     250   120                                      26   700       700     710     250   120                                      ______________________________________                                    

                                      TABLE VI                                    __________________________________________________________________________    MECHANICAL PROPERTIES OF POLYMERS                                                                 %             Flex             VPS                        Monomers       Tensile                                                                            Elong-                                                                             TM ×                                                                        Flex Mod ×                                                                        °C.                                                                            Blister                                                                           0  7  14 21                No.                                                                              q   r   s   Strength                                                                           ation                                                                              10.sup.6                                                                          Strength                                                                           10.sup.6                                                                           HDT Region                                                                            Rating                                                                            Days                                                                             Days                                                                             Days                                                                             Days              __________________________________________________________________________    1  0.5 0.5 1.0 4050 0.3  0.82                                                                              --   --   --  X   16.0                                                                              fail                                                                             fail                                                                             -- --                *2 0.5 0.5 1.0 6680 0.5  2.04                                                                              12810                                                                              1.5  214 X   16.0                           3  0.5 0.5 0.667                                                                             --   --   --  14660                                                                              1.44 207 None                                                                              16.0                           *4 0.5 0.5 0.667                                                                             --   --   --  16340                                                                              1.94 233 None                                                                              16.0                           5  0.387                                                                             0.617                                                                             0.667                                                                             --   --   --  21610                                                                              2.03 198 C   16.0                                                                              pass                                                                             pass                                                                             -- --                *6 0.387                                                                             0.617                                                                             0.667                                                                             --   --   --  19330                                                                              2.4  220 C   13.5                           7  0.446                                                                             0.554                                                                             0.538                                                                             --   --   --  15990                                                                              1.48 198 C   10.9                                                                              pass                                                                             pass                                                                             -- --                *8 0.446                                                                             0.554                                                                             0.538                                                                             --   --   --  15800                                                                              1.77 229 C   8.0                            9  0.6 0.4 0.5 --   --   --  12800                                                                              1.27 238 A   9.0 fail                                                                             fail                                                                             -- --                10 0.6 0.4 0.5 --   --   --  12180                                                                              1.51 243 A   9.0                            11 0.6 0.4 0.5 5600  0.51                                                                              1.0 13600                                                                              0.95 225 A   9.0                            *12                                                                              0.6 0.4 0.5 8700  0.55                                                                              1.5 13600                                                                              1.58 264 A   6.1                            13 0.6 0.4 0.5 18400                                                                               0.92                                                                              2.2 19400                                                                              1.65 283 A   7.3                            *14                                                                              0.6 0.4 0.5 14600                                                                               0.76                                                                              2.5 18800                                                                              1.68 288 A   11.3                           15 0.45                                                                              0.55                                                                              0.5 7960 0.4  1.86                                                                              20160                                                                              1.57 246 c   7.2 pass                                                                             pass                                                                             pass                                                                             pass              16 0.45                                                                              0.55                                                                              0.5 5390 0.2  1.89                                                                              19504                                                                              1.69 240 C   2.8                            *17                                                                              0.45                                                                              0.55                                                                              0.5 8830 0.3  2.6 16801                                                                              1.89 250 C   1.1 pass                       *18                                                                              0.45                                                                              0.55                                                                              0.5 --   --   --  18920                                                                              1.94 259 C   5.3                            19 0.5 0.5 0.4285                                                                            --   --   --  21200                                                                              1.81 229 A, C                                                                              9.0                            *20                                                                              0.5 0.5 0.4285                                                                            --   --   --  19720                                                                              1.82 246 A, C                                                                              9.0                            21 0.5 0.5 0.4285                                                                            6320 0.4  1.63                                                                              16990                                                                              1.4  245 A, C                                                                              8.0 pass                                                                             pass                                                                             pass                                                                             pass              *22                                                                              0.5 0.5 0.4285                                                                            11360                                                                               0.61                                                                              2.18                                                                              15670                                                                              1.83 269 A, C                                                                              9.6                            23 0.4142                                                                            0.5858                                                                            0.4285                                                                            --   --   --  25510                                                                              2.07 222 C   10.9                                                                              pass                                                                             pass                                                                             -- --                *24                                                                              0.4142                                                                            0.5858                                                                            0.4285                                                                            --   --   --  24370                                                                              2.08 225 C   9.0                            25 0.4142                                                                            0.5858                                                                            0.4285                                                                            --   --   --  18680                                                                              1.63 219 C   4.2 pass                                                                             pass                                                                             -- --                *26                                                                              0.4142                                                                            0.5858                                                                            0.4285                                                                            --   --   --  19780                                                                              1.88 239 C   2.0                            27 0.470                                                                             0.530                                                                             0.30                                                                              --   --   --  18470                                                                              2.01 264 C   0.3                            __________________________________________________________________________     *30% glass filled                                                        

                  TABLE VII                                                       ______________________________________                                        FIBER RATING OF POLYMERS                                                      Monomers                                                                           q          r          s       Fiber                                      No.  moles   %      moles %    moles %   Rating                                                                              Region                         ______________________________________                                         1   1.0     21     0.0   0    3.7   79  3-A   C                               2   0.0     0      1.0   33   2.0   67  3-A   C                               3   0.7     23     0.3   10   2.0   67  0                                     4   0.3     10     0.7   23   2.0   67  0                                     5   0.75    30     0.25  10   1.5   60  0                                     6   0.5     20     0.5   20   1.5   60  0                                     7   0.2     8      0.8   32   1.5   60  1                                     8   0.1     4      0.9   36   1.5   60  3     C                               9   0.0     0      1.0   40   1.5   60  3     C                              10   0.0     0      1.0   40   1.5   60  3     C                              11   0.3     13     0.7   31   1.25  56  3     C                              12   0.7     31     0.3   13   1.25  56  0                                    13   0.0     0      1.0   44   1.25  56  1                                    14   0.4     18     0.6   27   1.25  56  1                                    15   0.5     25     0.5   25   1.0   50  0                                    16   0.6     30     0.4   20   1.0   50  0                                    17   0.5     25     0.5   25   1.0   50  0                                    18   0.2     10     0.8   40   1.0   50  3     C                              19   0.1     5      0.9   45   1.0   50  1                                    20   0.0     0      1.0   50   1.0   50  1                                    21   0.0     0      1.0   57   0.75  43  0                                    22   0.2     11     0.8   46   0.75  43  3     C                              23   0.4     23     0.6   34   0.75  43  3     C                              24   0.5     28.5   0.5   28.5 0.75  43  1                                    25   0.8     46     0.2   11   0.75  43  0                                    26   0.666   38     0.333 19   0.75  43  0                                    27   0.5     30     0.5   30   0.667 40  0                                    28   0.383   23     0.617 37   0.667 40  0                                    29   0.6     37     0.4   25   0.6   38  0                                    30   0.4616  30     0.5384                                                                              35   0.538 35  0                                    31   0.54    35     0.46  30   0.54  35  1     A                              32   0.446   29     0.554 36   0.538 35  0                                    33   0.0     0      1.0   67   0.5   33  0                                    34   0.6     40     0.4   27   0.5   33  0     A                              35   0.6     40     0.4   27   0.5   33  0     A                              36   0.6     40     0.4   27   0.5   33  0                                    37   0.45    30     0.55  37   0.5   33  2                                    38   0.45    30     0.55  37   0.5   33  1                                    39   0.45    30     0.55  37   0.5   33  2                                    40   0.45    30     0.55  37   0.5   33  2-L                                  41   0.45    30     0.55  37   0.5   33  1                                    42   0.45    30     0.55  37   0.5   33  1                                    43   0.45    30     0.55  37   0.5   33  2-L                                  44   0.45    30     0.55  37   0.5   33  2                                    45   0.3     20     0.7   47   0.5   33  3     C                              46   0.5     35     0.5   35   0.4285                                                                              30  0     A                              47   0.5     35     0.5   35   0.4285                                                                              30  2                                    48   0.4142  29     0.5858                                                                              41   0.4285                                                                              30  2-L                                  49   0.533   40     0.467 35   0.33  25  2     A                              50   0.47    36     0.53  41   0.3   23  1-2                                  51   0.44    34     0.56  43   0.29  23  3-L   C                              52   0.44    34     0.56  43   0.29  23  2                                    53   0.44    34     0.56  43   0.29  23  3-L   C                              54   0.44    34     0.56  43   0.29  23  3     C                              55   0.44    34     0.56  43   0.29  23  2     A                              56   0.4     31     0.6   47   0.29  22  2                                    57   0.6     48     0.4   32   0.25  20  1     A                              58   0.5     40     0.5   40   0.25  20  2     A                              59   0.0     0      1.0   80   0.25  20  2-A                                  60   0.45    36     0.55  44   0.25  20  3     C                              61   0.3     24     0.7   56   0.25  20  1                                    62   0.4     33     0.6   49   0.22  18  2                                    63   0.5     42     0.5   42   0.2   16  2                                    64   0.56    48     0.44  37   0.176 15  1                                    65   0.45    38     0.55  47   0.176 15  2                                    66   0.61    52     0.39  33   0.18  15  1                                    67   0.4118  35     0.5882                                                                              50   0.176 15  3     C                              68   0.4118  35     0.5882                                                                              50   0.176 15  1                                    69   0.4118  35     0.5882                                                                              50   0.176 15  1                                    70   0.42    38     0.58  52   0.11  10  2                                    71   0.55    50     0.45  40   0.11  10  1                                    72   0.48    43     0.52  47   0.11  10  1                                    73   0.0     0      1.0   90   0.1   10  1                                    74   0.7     64     0.3   27   0.1    9  0                                    75   0.5     45.5   0.5   45.5 0.1    9  3     C                              76   0.3     27     0.7   64   0.1    9  1                                    77   0.45    36     0.55  44   0.25  20  2                                    78   0.5     42     0.5   42   0.2   16  2                                    79   0.42    34     0.58  46   0.25  20  2                                    80   0.470   36     0.530 41   0.30  23  2     C                              ______________________________________                                    

                  TABLE VIII                                                      ______________________________________                                        BLENDS OF POLYESTERS (a) and (b)                                              Polyester (weight %)                                                          Test    (a)     (b)        (b)   % wt. of                                     No.     P-1     B-1        B-2   Glass Fiber                                  ______________________________________                                         1      100.0   --         --    --                                            2      70.0    --         --    30.sup.(1)                                    3      63.0    7.0        --    30.sup.(1)                                    4      55.0    15.0       --    30.sup.(1)                                    5      42.0    28.0       --    30.sup.(1)                                    6      0.0     70.0       --    .sup.  30.sup.(1)(2)                          7      100.0   --         0.0   --                                            8      90.0    --         0.0   --                                            9      78.6    --         21.4  --                                           10      50.0    --         50.0  --                                           11      21.4    --         78.6  --                                           12      10.0    --         90.0  --                                           13      0.0     --         100.0 --                                           14      70.0    --         0.0   30.sup.(1)                                   15      63.0    --         7.0   30.sup.(1)                                   16      55.0    --         15.0  30.sup.(1)                                   17      35.0    --         35.0  30.sup.(1)                                   18      15.0    --         55.0  30.sup.(1)                                   19      7.0     --         63.0  30.sup.(1)                                   20      0.0     --         70.0  30.sup.(1)                                   ______________________________________                                         .sup.(1) Henry and Frick (now Fibertec), untreated 3016 (1/16") milled        glass fiber.                                                                  .sup.(2) Based on OC497 glass roving (OwensCorning).                     

                                      TABLE IX                                    __________________________________________________________________________    PROPERTIES OF POLYESTER BLENDS OF TABLE VII                                   Test                                                                             Injection Molding                                                                      HDT Blister                                                                            Flexural                                                                             Flexural Modulus (DMA) (psi × 10.sup.6)                                 at                                                No.                                                                              Stock Temp (°C.)                                                                (°C.)                                                                      Rating.sup.(1)                                                                     Strength (psi)                                                                       20° C.                                                                      200° C.                                                                     250° C.                                                                     300° C.                     __________________________________________________________________________    1  446      250 15.0 18,500 2.03 0.83 0.57 0.36                               2  433      264 13.9 13,380 2.25 0.83 0.52 0.31                               3  420      267 8.2  25,800 2.65 0.97 0.62 0.35                               4  390      261 0.07 28,480 2.39.sup.(2)                                                                       0.85 0.54 0.29                               5  379      224 0.0  17,680 2.02 0.53 0.29 0.10                               6  358      272 0.0  24,070 1.97 0.95 0.78 0.42                               __________________________________________________________________________     .sup.(1) Blister rating: 0 = best; 16 = worst.                                .sup.(2) Value at 30° C.                                          

                                      TABLE X                                     __________________________________________________________________________    PROPERTIES OF POLYESTER BLENDS OF TABLE VII                                   Tensile        Flexural                                                       Test                                                                             Strength                                                                            Modulus                                                                             Elong.                                                                             Strength                                                                           Modulus                                                                             HDT  Blister                                                                            DMA (psi × 10.sup.6) at                                                 (°C.)                         No.                                                                              (psi) (psi × 10.sup.6)                                                              (%)  (psi)                                                                              (psi × 10.sup.6)                                                              (°C.)                                                                       Rating.sup.(1)                                                                     30 50 100                                                                              150 200                                                                              250                                                                              300               __________________________________________________________________________    Neat                                                                           7  8,900                                                                              1.18  0.80 14,400                                                                             1.35  248.8                                                                              11.3 1.61                                                                             1.52                                                                             1.29                                                                             1.11                                                                              0.72                                                                             0.47                                                                             0.28               8 12,310                                                                              2.27  0.76 18,400                                                                             1.64  252.6                                                                              1.2  1.80                                                                             1.71                                                                             1.41                                                                             1.08                                                                              0.73                                                                             0.48                                                                             0.23               9 19,942                                                                              3.46  0.86 22700                                                                              1.99  264.0                                                                              0.28 2.13                                                                             2.02                                                                             1.60                                                                             1.22                                                                              0.88                                                                             0.58                                                                             0.27              10 21,386                                                                              4.50  1.10 23,200                                                                             1.65  256.9                                                                              0.0  1.56                                                                             1.49                                                                             1.15                                                                             0.77                                                                              0.55                                                                             0.36                                                                             0.14              11 21,116                                                                              4.54  1.00 22,000                                                                             1.62  266.3                                                                              0.0  1.45                                                                             1.37                                                                             1.04                                                                             0.75                                                                              0.61                                                                             0.47                                                                             0.26              12 14,200                                                                              3.81  0.72 22,100                                                                             1.92  299.7                                                                              0.0  1.46                                                                             1.38                                                                             1.06                                                                             0.85                                                                              0.76                                                                             0.63                                                                             0.45              13 17,550                                                                              4.31  0.62 22,200                                                                             2.42  346.2                                                                              2.1  2.60                                                                             2.48                                                                             1.94                                                                             1.67                                                                              1.57                                                                             1.42                                                                             1.19              30% Glass Filled                                                              14  7,880                                                                              1.50  0.6  13,400                                                                             1.65  259.5                                                                              9.2  1.61                                                                             1.52                                                                             1.29                                                                             1.11                                                                              0.72                                                                             0.47                                                                             0.28              15 13,221                                                                              2.61  0.9  19,100                                                                             1.99  271.5                                                                              1.6  2.34                                                                             2.25                                                                             1.89                                                                             1.46                                                                              0.98                                                                             0.66                                                                             0.35              16 17,264                                                                              2.66  1.0  23,000                                                                             2.17  272.4                                                                              0.07 2.52                                                                             2.40                                                                             1.99                                                                             1.58                                                                              1.10                                                                             0.75                                                                             0.38              17 19,667                                                                              2.40  2.0  24,800                                                                             1.83  256.4                                                                              0.13 1.94                                                                             1.86                                                                             1.51                                                                             1.10                                                                              0.82                                                                             0.59                                                                             0.25              18 18,117                                                                              2.26  2.0  22,500                                                                             1.75  284.2                                                                              0.66 1.84                                                                             1.73                                                                             1.35                                                                             1.05                                                                              0.90                                                                             0.73                                                                             0.47              19 17,760                                                                              2.91  1.7  23,800                                                                             1.91  310.0                                                                              0.07 1.99                                                                             1.89                                                                             1.51                                                                             1.22                                                                              1.09                                                                             0.94                                                                             0.70              20 19,400                                                                              2.65  1.3  21,700                                                                             2.37  348.4                                                                              0.26 2.81                                                                             2.66                                                                             2.08                                                                             1.79                                                                              1.71                                                                             1.58                                                                             1.34              __________________________________________________________________________     .sup.(1) Blister rating: 0 = best; 16 = worst.                           

                  TABLE XI                                                        ______________________________________                                        ROOM TEMPERATURE IZOD DATA                                                    OF GLASS FILLED BLENDS OF TABLE VII                                           Test         Notched  Unnotched                                               No.          (ft-lb/in.)                                                      ______________________________________                                        14           0.70     2.00                                                    15           0.90     2.70                                                    16           1.22     5.61                                                    17           2.30     12.80                                                   18           2.50     15.30                                                   19           2.40     17.50                                                   20           2.30     8.70                                                    ______________________________________                                    

                  TABLE XII                                                       ______________________________________                                        BLENDS OF POLYESTERS                                                          Polyester (Weight %)                                                          Test (a)         (b)    (b)  (b)   Glass Melt Temp.                           No.  P-1         B-1    B-2  B-3   Fiber.sup.(1)                                                                       (°C.)                         ______________________________________                                        21   100.0 (control)                                                                           --     --   --    --    383                                  22    78.6       --     --   21.4  --    373                                  23    20.0       --     --   80.0  --    321                                  24   (control)   --     --   100.0 --    286                                  ______________________________________                                         .sup.(1) Henry and Frick (now Fibertec), 1/16" milled glass fiber.       

                                      TABLE XIII                                  __________________________________________________________________________    PROPERTIES OF BLENDS OF TABLE XII                                             Tensile          Flexural                                                     Test                                                                             Strength                                                                           Modulus                                                                            Elong                                                                             Strength                                                                           Modulus                                                                            HDT Blister                                                                           DMA modulus (psi × 10.sup.6)                                            at:                                        No.                                                                              (psi)                                                                              (psi 10.sup.6)                                                                     (%) (psi)                                                                              (psi 10.sup.6)                                                                     (°C.)                                                                      Rating                                                                            30° C.                                                                     50° C.                                                                     100° C.                                                                    150° C.                                                                    200° C.                                                                    250°                                                                       300°        __________________________________________________________________________                                                               C.                 Neat                                                                          21  8,900                                                                             1.18 0.8 14,400                                                                             1.35 248.8                                                                             15.0                                                                              1.32                                                                              1.24                                                                              1.01                                                                              0.81                                                                              0.51                                                                              0.35                                                                              0.20               22 11,300                                                                             1.55 0.7 18,800                                                                             1.49 236.1                                                                             6.0 1.76                                                                              1.64                                                                              1.27                                                                              0.84                                                                              0.53                                                                              0.31                                                                              0.18               23 19,800                                                                             2.02 1.6 --   --   176.7                                                                             16.0                                                                              1.52                                                                              1.39                                                                              0.90                                                                              0.33                                                                              0.16                                                                              0.03                                                                              --                 24 18,200                                                                             1.40 3.3 20,400                                                                             1.20 189.4                                                                             16.0                                                                              1.32                                                                              1.90                                                                              0.69                                                                              0.30                                                                              0.20                                                                              0.06                                                                              --                 __________________________________________________________________________

                                      TABLE XIV                                   __________________________________________________________________________     BLENDS OF (A) POLYMER (REGION C)                                             __________________________________________________________________________                       Tensile   Flex                                             %  % %   %  Tensile                                                                            % Mod ×                                                                        Flex Mod ×                                                                            Blister                                 A  B Glass                                                                             TiO.sub.2                                                                        Strength                                                                           El                                                                              10.sup.6                                                                           Strength                                                                           10.sup.6                                                                           HDT Rating                                  __________________________________________________________________________    55 15                                                                              30  -- 17950                                                                              1.0                                                                             2.98 23550                                                                              2.27 223  0.13                                   55 15                                                                              30  -- --   --                                                                              --   21850                                                                              2.22 231 3.4                                     63  7                                                                              30  -- 13250                                                                              0.6                                                                             2.5  21130                                                                              2.20 248 4.3                                     63  7                                                                              30  -- --   --                                                                              --   21890                                                                              2.24 247 4.1                                     54 14                                                                              29  3  --   --                                                                              --   24114                                                                              1.96 201 3.2                                      68*                                                                              0                                                                              29  3  --   --                                                                              --   17560                                                                              1.97 253 9.0                                     __________________________________________________________________________    A:                                                                              0.45 moles terephthalic acid                                                  0.55 moles isophthalic acid                                                   0.50 moles p-hydroxybenzoic acid                                              1.0 moles hydroquinone                                                      B:                                                                              0.75 moles terephthalic acid                                                  0.25 moles isophthalic acid                                                   3.0 p-hydroxybenzoic acid                                                     1.0 biphenol                                                            

We claim:
 1. A high modulus, high strength, melt-processible polyesterconsisting essentially of recurring units (I), (II), (III) and (IV):##STR19## wherein said polyester has a melting point in the range offrom about 250° to 360° C.
 2. The polyester of claim 1 having a heatdistortion temperature of about 240 under a load of 264 psi when filledwith 30 weight percent glass fiber and a fiber pull rating of at least2.
 3. The polyester of claim 1 wherein the sum of the number of units of(II) and (III) is approximately equal to the number of unit (I); andunit (IV) ranges from about 0.075 to 1.5 moles per each mole of unit(I).
 4. A high modulus, high strength, melt-processible polyesterconsisting essentially of recurring units (I), (II), (III), and (IV):##STR20## having a melting point in the range of from about 250° to 360°C., and when filled with 30 percent by weight glass fibers, has an HDTof about 240° C. under a load of 264 psi and ability to form strongfibers.
 5. The polyester of claim 4 wherein the percentage of units (I),(II), (III) and (IV) falls within area C circumscribed on the attachedtriangular phase diagram of FIG.
 1. 6. The polyester of claim 4 whereinthe sum of the number of units of (II) and (III) is approximately equalto (I); and unit (IV) ranges from about 0.075 to 1.5 moles per each moleof unit (I).
 7. The method of preparing the polyester of claim 1 whichcomprises reacting hydroquinone, isophthalic acid, terephthalic acid andhydroxybenzoic acid in a solvent comprising an anhydride of a lowermonocarboxylic acid.
 8. The process of claim 7 wherein said reaction iscarried out in the presence of a salt selected from the group consistingof an alkaline earth metal salt and an alkali metal salt.
 9. The methodof preparing the polyester of claim 4 which comprises reactinghydroquinone, isophthalic acid, terephthalic acid and hydroxybenzoicacid in a solvent comprising an anhydride of a lower monocarboxylicacid.
 10. A high modulus, high strength, melt-procesible polyesterconsisting essentially of recurring units (I), (II), (III), and (IV)falling within area C on the attached triangular phase diagram of FIG.1.